Optimization of Injection-Compression Molding Processing Conditions for Fresnel Lens Based on Optical Performance and Geometry Deformation Considerations

Mold flow simulations are performed to determine the processing conditions which optimize the optical performance and geometry deformation of a plastic Fresnel lens manufactured using the injection-compression molding (ICM) technique. Due to the quality requirements of plastic optical components in ICM manufacturing (it is hoped to achieve the goals of minimum deformation and minimum birefringence), and pursuing the above two conflicting objectives and meeting the quality requirements at the same time is the best product optimization. The analysis process is to optimize optical path difference and optical axial displacement individually by Taguchi method, and two sets of processing parameters are obtained respectively. Based on these data, a set of processing parameters that can optimize two objectives at the same time is obtained by using the grey relational analysis. If the above process cannot obtain optimal result, the fixed factor method can fix the most significant factor and continue to process the optimization analysis of the remaining factors. The results show that the presented method can indeed solve the problems of dual-objectives optimization and large differences in the influence of factors.