Injection compression molding (ICM) provides enhanced optical performances of molded polymer optics in terms of birefringence and transmission of light compared to Injection molding (IM). Nevertheless, ICM requires case-dedicated process optimization to ensure that the required high accuracy geometrical replication is achieved, particularly especially in the case of surface micro-features. In this study, two factorial designs of experiments (DOE) were carried out to investigate the replication capability of IM and ICM on a micro structured Fresnel lens. A laser scanning confocal microscope was employed for the quality control of the optical components. Thus, a detailed uncertainty budget was established for the dimensional measurements of the replicated Fresnel lenses, considering specifically peak-to-valley (PV) step height and the pitch of the grooves. Additional monitoring of injection pressure allowed for the definition of a manufacturing signature, namely, the process fingerprint for the evaluation of the replication fidelity under different process conditions. Moreover, considerations on the warpage of parts were related to a manufacturing signature of the molding processes. At last, the global part mass average and standard deviation were measured to correlate local geometrical replication performances with global part quality trends.
Keywords: Fresnel lenses; confocal microscopy; injection compression molding; injection molding; manufacturing signature; micro structures replication; optical quality control; optimization; process fingerprint; uncertainty budget.