A review of the techniques for the mold manufacturing of micro/nanostructures for precision glass molding

Micro/nanostructured components play an important role in micro-optics and optical engineering,tribology and surface engineering,and biological and biomedical engineering,among other fields.Precision glass molding technology is the most efficient method of manufacturing micro/nanostructured glass components,the premise of which is meld manufacturing with complementary micro/nanostructures.Numerous mold manufacturing methods have been developed to fabricate extremely small and high-quality micro/nanostructures to satisfy the demands of functional micro/nanostructured glass components for various applications.Moreover,the service performance of the mold should also be carefully considered.This paper reviews a variety of technologies for manufacturing micro/nanostructured molds.The authors begin with an introduction of the extreme requirements of mold materials.The following section provides a detailed survey of the existing micro/nanostructured mold manufacturing techniques and their corresponding mold materials,including nonmechanical and mechanical methods.This paper concludes with a detailed discussion of the authors recent research on nickel-phosphorus(Ni-P)mold manufacturing and its service performance.

A new fabricating technique of refiner plate

It was discussed how refiner plate is produced by a new process, such as three dimension making die with computer technology, shell molding, optimizing the alloy and controlling shakeout time with computer. Results confirmed that lead-time was decreased and product customization was improved in making die by using computer technology. At the same time, precision molding can decrease the reject ratio of refiner plates, and optimizing the alloy and shakeout time can eliminate the need for heat treatment. The new fabricating process showed several advantages over the traditional process in increasing toughness, better casting precision, elimination of the annealing treatment stage and raising production efficiency.

Precision glass molding： Toward an optimal fabrication of optical lenses

It is costly and time consuming to use machining processes, such as grinding, polishing and lapping, to produce optical glass lenses with complex features. Precision glass molding （PGM） has thus been developed to realize an efficient manufacture of such optical components in a single step. However, PGM faces various technical challenges. For example, a PGM process must be carded out within the super-cooled region of optical glass above its glass transition temperature, in which the material has an unstable non-equilibrium structure. Within a narrow window of allowable tempera- ture variation, the glass viscosity can change from 10s to 10t2 Pa-s due to the kinetic fragility of the super-cooled liquid. This makes a PGM process sensitive to its molding temperature. In addition, because of the structural relaxa- tion in this temperature window, the atomic structure that governs the material properties is strongly dependent on time and thermal history. Such complexity often leads to residual stresses and shape distortion in a lens molded, causing unexpected changes in density and refractive index. This review will discuss some of the central issues in PGM processes and provide a method based on a manufacturing chain consideration from mold material selection, property and deformation characterization of optical glass to process optimization. The realization of such optimization is a necessary step for the Industry 4.0 of PGM.