Dick, L.L.DickRisse, S.S.RisseTünnermann, A.A.Tünnermann2022-03-052022-03-052016https://publica.fraunhofer.de/handle/publica/24594710.1515/aot-2016-0023Modern injection molding processes offer a cost-efficient method for manufacturing high precision plastic optics for high volume applications. Besides form deviation of molded freeform optics, internal material stress is a relevant influencing factor for the functionality of a freeform optics in an optical system. This paper illustrates dominant influence parameters of an injection molding process relating to form deviation and internal material stress based on a freeform demonstrator geometry. Furthermore, a deterministic and efficient way for 3D mold correcting of systematic, asymmetrical shrinkage errors is shown to reach micrometer range shape accuracy at diameters up to 40 mm. In a second case, a stress-optimized parameter combination using unusual molding conditions was 3D corrected to reach high precision and low stress freeform polymer optics.en535journal article