Article
Optics
Jingyu Mo, Xuefeng Chang, Duoji Renqing, Jinpeng Zhang, Longxing Liao, Shanming Luo
Summary: This study presents a novel type of concave lens array on an aspheric convex substrate (CLAACs) composed of an aspheric substrate and a spherical concave subeye array. A method for designing, fabricating, and characterizing the CLAACs is proposed. The results demonstrate the feasibility and effectiveness of this method for designing and fabricating lens arrays with complex discontinuous surfaces.
Article
Engineering, Electrical & Electronic
Pin-Chuan Chen, Cing-Sung Yeh, Chih-Yu Hsieh
Summary: This study applied defocusing to digital light processing (DLP) stereolithography to fabricate microlens arrays (MLAs) within 1 s. The effects of exposure energy, defocus distance, and a diameter adjustment algorithm were investigated to achieve MLAs with desired dimensions. The results showed that the proposed fabrication method is suitable for various MLA designs, with nanoscale surface roughness and good image quality.
SENSORS AND ACTUATORS A-PHYSICAL
(2022)
Article
Optics
Yang Shu, Wenchen Zhou, Zhixiong Zhou, Allen Y. Yi
Summary: In this study, a rapid non-isothermal imprinting process for Fresnel lens arrays was proposed, which can be carried out at room temperature to greatly reduce thermal cycle time and energy consumption. The process allows for production of high-quality microlenses with a high precision surface finish.
Review
Chemistry, Physical
Nurul Hidayah Mohamad Huzaim, Shayfull Zamree Abd Rahim, Luqman Musa, Abdellah El-hadj Abdellah, Mohd Mustafa Al Bakri Abdullah, Allan Rennie, Rozyanti Rahman, Sebastian Garus, Katarzyna Bloch, Andrei Victor Sandu, Petrica Vizureanu, Marcin Nabialek
Summary: Rapid tooling and additive manufacturing are widely used in the industry, meeting the increasing demand for low-cost products and improving product quality. The development of these technologies allows for testing performance and overcoming surface defects. The implementation of rapid heating cycle molding injection methods further enhances product quality and production efficiency.
Article
Nanoscience & Nanotechnology
Mengnan Wu, Lan Jiang, Xiaowei Li, Zhikun Xiang, Peng Yi, Yang Liu, Leyi Zhang, Xibiao Li, Zhi Wang, Xiangyu Zhang
Summary: In this study, a microheater-integrated MLA (& mu;H-MLA) was fabricated on the same substrate using femtosecond laser processing, providing high light transmittance, durability, and fog removal efficiency. The & mu;H-MLA showed stable performance for over 24 hours under continuous operation, as well as under long time ultrasonic vibration and mechanical friction. It successfully removed fog covering the entire face within 14 seconds, with a rapid response time of 17 seconds and a high working temperature of 188 & DEG;C. Furthermore, this fabrication method was proven to be applicable in large areas and curved surface environments.
ACS APPLIED MATERIALS & INTERFACES
(2023)
Article
Materials Science, Ceramics
Tianfeng Zhou, Zihao Zeng, Qian Yu, Jia Zhou, Peng Liu, Xibin Wang
Summary: This paper proposes a multi-step molding method to avoid gas trapping in microlens arrays during precision glass molding (PGM) and improve their accuracy. The defect formation mechanism caused by trapped gas is investigated, and the effect of molding pressure is analyzed. A numerical model of the mold-nitrogen-glass interface is established to predict the minimum number of PGM steps required to reduce gas-induced defects. Experimental results validate the numerical model, showing a significant reduction in defect height with a three-step PGM process. The molded microlens array has a peak-to-valley value of 0.38 μm and a surface roughness Ra of 3.5 nm, making it suitable for high-precision glass microlens array fabrication.
INTERNATIONAL JOURNAL OF APPLIED GLASS SCIENCE
(2023)
Article
Engineering, Manufacturing
Chunxin Liu, Taras Oriekhov, Cherrie Lee, Clarissa M. Harvey, Michael Fokine
Summary: This study demonstrates that rapid manufacturing of high purity fused silica glass micro-optics can be achieved using a filament-based glass 3D printer, resulting in fully dense lenses with uniform focal lengths and good imaging performance.
3D PRINTING AND ADDITIVE MANUFACTURING
(2022)
Article
Nanoscience & Nanotechnology
Wangyang Zhang, Weishan Yan, Haonian Zheng, Chaopeng Zhao, Duo Liu
Summary: This study demonstrates laser-engineered polydimethylsiloxane (PDMS) as a versatile and highly efficient platform for water manipulation. The obtained superhydrophobic PDMS material exhibits excellent stability and can be widely applied in areas such as oil/water separation and water collection.
ACS APPLIED MATERIALS & INTERFACES
(2021)
Article
Chemistry, Analytical
Fan Zhang, Qing Yang, Hao Bian, Xun Hou, Feng Chen
Summary: A rapid and single-step method for fabricating a zinc selenide concave microlens array using high-speed line-scanning of a femtosecond laser pulse was presented. Approximately 1.1 million microlenses were fabricated within 36 minutes, with controlled size and high transparency at infrared wavelengths. The method shows great potential for developing ZnSe-based micro-optical devices.
Article
Engineering, Electrical & Electronic
Abolfazl Zolfaghari, Lin Zhang, Wenchen Zhou, Allen Y. Yi
Summary: The research introduces a process using electroforming of nickel to replicate mold inserts directly from a plastic microlens array, enabling high-volume production. This method offers a promising technique for manufacturing microlens arrays with complex optical components.
MICROELECTRONIC ENGINEERING
(2021)
Article
Polymer Science
Chil-Chyuan Kuo, Xin-Yu Pan
Summary: Metal injection molding (MIM) is a manufacturing process that combines plastic injection molding and powder metallurgy. Two types of injection molds for MIM were developed using conventional mold steel and aluminum-filled epoxy resins. The characteristics of a mold made by rapid tooling technology (RTT) were evaluated and compared with a conventional machining method through the MIM process. It was found that the mold made with aluminum-filled epoxy resin had a service life of 1300 molding cycles with an average surface roughness of 158 nm. Its service life was only 1.3% of the conventional mold steel, while the manufacturing cost was reduced by 30.4% and the manufacturing time was saved by 30.3% compared to the conventional machining method.
Article
Optics
Changfu Lang, Chuang Li, Hang Fu, Sui Bo, Chao Yang, Changxi Xue
Summary: The machining of freeform surfaces is a current research hotspot. A hybrid slow-fast tool servo method combining slow tool servo (STS) and fast tool servo (FTS) was proposed to machine large steep freeform surfaces. Experimental studies showed that this method improved processing efficiency and achieved good surface roughness.
Article
Optics
Julian L. Pita Ruiz, Lucas G. Rocha, Jun Yang, Sukru Ekin Kocabas, Ming-Jun Li, Ivan Aldaya, Paulo Dainese, Lucas H. Gabrielli
Summary: This paper presents a high-efficiency vertical grating coupler designed for LP01x, LP11ax, and LP11bx modes in a graded-index few-mode fiber. The coupler consists of a non-uniform straight bidirectional grating, two mode-selective directional couplers, and two tapers. Fabricated through e-beam lithography, the device achieved coupling efficiencies of -3.0 dB, -3.6 dB, and -3.4 dB for LP01x, LP11ax, and LP11bx modes, respectively. The proposed CMOS-compatible coupler demonstrates its potential as a key component in high-capacity networks utilizing space division multiplexing on few-mode fibers.
Article
Automation & Control Systems
Chil-Chyuan Kuo, Yun-Ray Tasi, Ming-Yang Chen, Zheng-Yu Yan
Summary: A cost-efficient approach for low-volume production of wax patterns was demonstrated in this study by integrating rapid tooling technology, low-pressure wax injection molding, and 3D optical inspection technologies. Dimensional compensation method was used to address dimensional changes, leading to significant cost savings and efficiency improvement in precision wax pattern fabrication.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Tianfeng Zhou, Jia Zhou, Tianxing Wang, Liheng Gao, Benshuai Ruan, Qian Yu, Wenxiang Zhao, Xibin Wang
Summary: Ultraprecision mold machining combined with precision glass molding is the most promising technology for mass production of glass microlens arrays. This study proposes a local spiral diamond milling method to fabricate high aspect-ratio MLAs and develops a toolpath generation algorithm. Each lenslet can be precisely machined by controlling the servo motions of the three translational axes, and the entire MLA can be generated by shifting the toolpath according to the MLA layout. The experimental results show that the fabricated mold and molded lenses have high profile accuracy and surface roughness, and exhibit good consistency.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Electrical & Electronic
Ruzhen Xu, Tianfeng Zhou, Rebecca Cheung
Summary: In this study, a novel method is proposed to fabricate concave MLAs on SiC substrates by using self-assembled silica microspheres as a template. This method overcomes the manufacturing challenges posed by the high hardness and brittleness of SiC.
MICROELECTRONIC ENGINEERING
(2021)
Article
Automation & Control Systems
Tianfeng Zhou, Benshuai Ruan, Qian Yu, Jia Zhou, Peng Liu, Wenxiang Zhao, Xibin Wang
Summary: This study proposes a method for machining MLAs on Ni-P plating, controls MLA sag precision within 20 nm through a precision tool setting method, and creates high-quality MLAs by optimizing tool settings and machining parameters.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Review
Engineering, Manufacturing
Tianfeng Zhou, Yupeng He, Tianxing Wang, Zhanchen Zhu, Ruzhen Xu, Qian Yu, Bin Zhao, Wenxiang Zhao, Peng Liu, Xibin Wang
Summary: Micro/nanostructured components play a crucial role in various fields, and precision glass molding technology is the most efficient manufacturing method. The service performance of the mold should be carefully considered.
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING
(2021)
Article
Materials Science, Ceramics
Tianfeng Zhou, Zifan Wang, Benshuai Ruan, Shuang Li, Qian Yu, Yupeng He, Ruzhen Xu, Jia Zhou, Wei Jiang, Fubin Ma, Xiaoqiang Yao, Peng Liu, Xibin Wang
Summary: This paper investigates the causes of blackening of leaded glass during precision glass molding (PGM) and proposes methods to prevent it. By establishing the redox reaction equation between Ni and Pb and a viscoelastic constitutive model of glass, the mechanism of blackening is identified and a preventive method is suggested.
CERAMICS INTERNATIONAL
(2022)
Article
Automation & Control Systems
Tianfeng Zhou, Chi Zhang, Yupeng He, Jia Zhou, Peng Liu, Bin Zhao, Xibin Wang
Summary: Chalcogenide glass is widely studied for its properties, and precision glass molding and single-point diamond turning are efficient methods for ChG processing, although challenges arise at high temperatures. A new process combining PGM and SPDT technologies can fabricate ChG aspheric lenses, increasing processing efficiency.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Optics
Tianfeng Zhou, Jia Zhou, Hailong Chen, Zifan Wang, Benshuai Ruan, Wenxiang Zhao, Xibin Wang
Summary: This paper analyzes the surface errors of a FAC fabricated by combining ultraprecision diamond cutting and precision glass molding, establishes an optical simulation model to analyze the effects of tool marks on optical defects, and carries out numerical calculations and experiments to verify the theoretical results. The study determines the critical conditions to eliminate diffractive fringes and improve the optical performance of the FAC.
Article
Chemistry, Analytical
Jiayu Li, Yuhan Cui, Qiucheng Xie, Tao Jiang, Siyuan Xin, Peng Liu, Tianfeng Zhou, Qin Li
Summary: The flow cytometer is a powerful and widely accepted measurement device in biological studies and clinical diagnostics. To meet the requirements of portable and point-of-care scenarios, a miniaturized flow cytometer based on an all-glass microfluidic chip (AG-UFCM) has been developed, which enables accurate blood analysis and four-part leukocyte differential count based on single fluorescence staining.
ANALYTICAL CHEMISTRY
(2023)
Article
Engineering, Industrial
Ziqi Chen, Qian Yu, Keita Shimada, Peng Liu, Yupeng He, Yao Hu, Xibin Wang, Tianfeng Zhou, Masayoshi Mizutani
Summary: This paper proposes an ultrasonic-assisted ultra-precision planing (UAUP) method for the fabrication of blazed gratings. The relationship between processing parameters and grating characteristic dimensions was established, and the feasibility of the UAUP method was verified.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Materials Science, Ceramics
Tianfeng Zhou, Zihao Zeng, Qian Yu, Jia Zhou, Peng Liu, Xibin Wang
Summary: This paper proposes a multi-step molding method to avoid gas trapping in microlens arrays during precision glass molding (PGM) and improve their accuracy. The defect formation mechanism caused by trapped gas is investigated, and the effect of molding pressure is analyzed. A numerical model of the mold-nitrogen-glass interface is established to predict the minimum number of PGM steps required to reduce gas-induced defects. Experimental results validate the numerical model, showing a significant reduction in defect height with a three-step PGM process. The molded microlens array has a peak-to-valley value of 0.38 μm and a surface roughness Ra of 3.5 nm, making it suitable for high-precision glass microlens array fabrication.
INTERNATIONAL JOURNAL OF APPLIED GLASS SCIENCE
(2023)
Article
Materials Science, Ceramics
Zhanchen Zhu, Tianfeng Zhou, Yupeng He, Qian Yu, Xibin Wang, Tao Yan, Jiwang Yan, Haihui Ruan
Summary: In this study, a novel two-step precision glass molding (PGM) process is proposed for the fabrication of chalcogenide (ChG) glasses with micro-nano structure arrays. A nickel-phosphorus (Ni-P) mold is used to transfer the antireflective micro-nano structure array to silicate glass, which is then used as a mold to replicate the structured surface onto the ChG glass. The results demonstrate high forming accuracy and favorable infrared optical transmission characteristics of the ChG glass micro-nano structure array, while the silicate glass proves to be a suitable mold material for the ChG glass molding process. This work provides a novel PGM technique for ChG glass materials.
CERAMICS INTERNATIONAL
(2023)
Article
Materials Science, Multidisciplinary
Zifan Wang, Tianfeng Zhou, Qian Yu, Xiaoqiang Yao, Peng Liu, Xibin Wang
Summary: Glass molding technology is widely used for mass production of glass components, with Ni-P plating as the mold material. However, the service life of Ni-P molds is reduced due to Ni atom diffusion at high temperatures. To address this, a Ti-DLC coating is applied to protect the mold surface. This study investigates the crystallization and diffusion of Ni atoms in both Ni-P molds and Ti-DLC coated Ni-P molds, finding that the Ti-DLC coating suppresses Ni atom diffusion while allowing Ni-P crystallization. The improved thermomechanical performance of the Ti-DLC coated Ni-P mold is demonstrated by the absence of microbumps after 80 molding cycles.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Engineering, Industrial
Yupeng He, Tianfeng Zhou, A. Senthil Kumar, Xibin Wang, Jiwang Yan
Summary: The shear interference and chip removal interference between different tool edges during non-free cutting are the main reasons for the deformation of micron-submicron grooves. This paper presents a new variable shear angle removal model to understand the material removal mechanism and cutting-induced deformation of micron-submicron grooves in non-free cutting. Finite element simulations and high-speed cutting experiments are conducted to analyze the cutting microstate and dynamic deformation of the micron-submicron grooves.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Chemistry, Multidisciplinary
Zhanchen Zhu, Tianfeng Zhou, Qian Yu, Xibin Wang, Jiaqing Xie, Tao Yan, Haihui Ruan, Chifai Cheung
Summary: The adhesion between glass mold and glass is a crucial issue in the glass molding process, which can be solved by analyzing the adhesion mechanism and using a special surface coating. By utilizing a spherical glass preform and a coated mold, high-precision glass microstructures can be fabricated.
Article
Engineering, Multidisciplinary
Tianfeng Zhou, Zhongqi Zhang, Jia Zhou, Bin Zhao, Xiaoqiang Yao, Xibin Wang, Junjian Hu, Jiyong Zeng
Summary: Rotary milling with diamond ball-end milling tools was used to fabricate a microlens array (MLA). The tool-setting error affects the positional accuracy of each lenslet and can be evaluated by the adjacency defect in the MLA. A quadrifoliate tool-setting method was developed to calculate and correct the tool-setting error based on the adjacency ridge. The proposed method reduced the setting error of the diamond ball-end milling tool to less than 1 μm, enabling the fabrication of an MLA with low position error.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Optics
Zifan Wang, Tianfeng Zhou, Qian Yu, Zihao Zeng, Xibin Wang, Junjian Hu, Jiyong Zeng
Summary: Fast-axis collimation (FAC) lens arrays are crucial in laser systems, and their precision can be improved through the development of an optical collimation system and the use of thermal compensation to correct for non-uniform thermal expansion.
OPTICS AND LASERS IN ENGINEERING
(2024)