Rapid fabrication of surface-relief plastic diffusers by ultrasonic embossing
Resource
OPTICS AND LASER TECHNOLOGY 42 5 794 798
Journal
Optics & Laser Technology
Pages
794-798
Date Issued
2010
Date
2010
Author(s)
Abstract
This paper discusses an innovative and effective ultrasonic embossing process, which enables the rapid fabrication of surface-relief plastic diffusers. The metallic mold bearing the microstructures is fabricated using a tungsten carbide turning machine. A 1500-W ultrasonic vibrator with an output frequency of 20 kHz was used to replicate the microstructure onto 1-mm-thick PMMA plates in the experiments. During ultrasonic embossing, the ultrasonic energy is converted into heat through intermolecular friction at the master mold/plastic plate interface due to asperities to melt the thermoplastic at the interface and thereby to replicate the microstructure. Under the proper processing conditions, high-performance plastic diffusers have been successfully fabricated. The cycle time required to successfully fabricate a diffuser is less than 2 s. The experimental results suggest that ultrasonic embossing could provide an effective way of fabricating high-performance plastic diffusers with a high throughput. © 2009 Elsevier Ltd. All rights reserved.
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Type
journal article
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