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Enhancement of high-resolution 3d inkjet-printing of optical freeform surfaces using digital twins

Sieber, Ingo; Thelen, Richard; Gengenbach, Ulrich

Abstract:
3D-inkjet-printing is just beginning to take off in the optical field. Advantages of this technique include its fast and cost-efficient fabrication without tooling costs. However, there are still obstacles preventing 3D inkjet-printing from a broad usage in optics, e.g., insufficient form fidelity. In this article, we present the formulation of a digital twin by the enhancement of an optical model by integrating geometrical measurement data. This approach strengthens the high-precision 3D printing process to fulfil optical precision requirements. A process flow between the design of freeform components, fabrication by inkjet printing, the geometrical measurement of the fabricated optical surface, and the feedback of the measurement data into the simulation model was developed, and its interfaces were defined. The evaluation of the measurements allowed for the adaptation of the printing process to compensate for process errors and tolerances. Furthermore, the performance of the manufactured component was simulated and compared with the nominal performance, and the enhanced model could be used for sensitivity analysis. The method was applied to a highly complex helical surface that allowed for the adjustment of the optical power by rotation. ... mehr

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Verlagsausgabe §
DOI: 10.5445/IR/1000129543
Veröffentlicht am 10.02.2021
Cover der Publikation
Zugehörige Institution(en) am KIT Institut für Automation und angewandte Informatik (IAI)
Institut für Mikrostrukturtechnik (IMT)
Publikationstyp Zeitschriftenaufsatz
Publikationsjahr 2021
Sprache Englisch
Identifikator ISSN: 2072-666X
KITopen-ID: 1000129543
Erschienen in Micromachines
Verlag MDPI
Band 12
Heft 1
Seiten Art.-Nr.: 35
Schlagwörter digital twin; modeling; simulation; additive manufacturing; 3D inkjet-printing; freeform optics; varifocal optics
Nachgewiesen in Dimensions
Scopus
Web of Science
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