Flexibility analysis on precision glass molding by finite element method simulation

In recent years, there has been a rising demand for highly precise glass optics, especially in sectors like lighting, automotive, laser technology, and renewable energies. This increase represents a significant challenge to the industry due to the growing complexity of optical systems and escalating production costs. Precision glass molding (PGM) is an established technology to manufacture precise and highly complex shaped glass optics by pressing a glass preform between two precisely manufactured molding tools into the desired final shape. Costs in process development can be reduced by using Finite Element Method (FEM) simulation to predict the glass flow and derive the optimal mold geometry. However, this is still limited to manufacture a specific lens design with a dedicated set of molding tools and parameters. In this investigation, FEM simulation tools were employed to analyze the possibility to manufacture different lens geometries with one mold insert pair. The study involved varying the process configuration, including molding force and temperature, in various combinations, followed by simulating the processes. The objective is to assess how alterations in process parameters influenced the shape of the molded lenses, aiming to determine the flexibility of the PGM process and optimize its efficiency.