Ahh, a bittersweet ending to our Optical Fabrication saga. This last feature will discuss lens fabrication through 3D printing, how it compares to other methods (Single Point Diamond Turning Machines & Silicone Molding), and its advantages and disadvantages.
We know what you are thinking. Sure, a 3D printed lens sounds cool, but will it be functional?
The only way to find out is to give it a try. We broke down the 3D printing method into seven simple steps. Remember, these steps assume that you have the design for your lens and have made all the calculations needed to ensure its desired shape.
Now that we are on the same page, let’s dive in!
Step 1: Materials
Choosing the material is a critical factor as to how your lens will turn out. The most common material for 3D printing lenses is acrylate monomer resin.
Step 2: Slicing
This step is straightforward yet demanding, especially if it’s your first time doing it.
Use a computer-aided program to change the settings to alter your stereolithography’s (SLA) way to print. Some settings include adding support for your print if needed (this will help the print come out with better quality).
Step 3: Printing
Once you slice your print, upload the file into the printer and begin printing. Depending on your lens’s size and complexity, you may have to wait a couple of hours.
Step 4: Post Processing
After the print is complete, grab the lens using gloves to clean it. Keep in mind that your print will have leftover resin from the tank, and resin in its liquid state can be dangerous. It is important to note that you should clean your print by using isopropyl alcohol (IPA) instead of water. Most liquid resins are not soluble in water but are soluble in alcohol. We recommend rinsing the print twice in different containers to get rid of as much liquid resin as possible.
Step 5: Curing
Now that your lens is clean and liquid resin-free, it is ready to be cured. This step is where your print fully hardens. If you don’t complete this step correctly, the print can be deformed.
You want to avoid any kind of deformation, as it will make the lens useless. Most SLA resins are UV reactive, which means UV light can cure them. Leave your lens under UV light to complete this process. (The amount of time it takes to cure will depend on the size of your lens).
Step 6: Sanding
Carefully sand your lens using high grit sandpaper and water to prevent scratching the surface. Stop sanding once you’ve reached desired smoothness.
Step 7: Polishing
Now that your lens has a smooth surface, it’s time to give it the final touch using a piece of cloth and polishing paste.
Congratulations! You have a 3D printed lens. Now that’s something to be proud of.
How does the 3D Printing Method Compare?
3D Printing may be in your best interest if you’re working with small lenses, prototypes or if you are on a time crunch.
Making lenses through the other methods mentioned in previous blogs ( SPDT Machines and Silicone Molding ) can take a long time. For example, depending on the material used, your part may take about 72 hours to fully cure through the silicone molding process.
The cost of 3D printing is much less expensive than the other methods. You can get promising results using affordable 3D printers such as fused deposition modeling (FDM) and stereolithography (SLA). But a downside is that you can only make your lens as big as the printing bed allows. For example, if you are using an affordable SLA, it won’t be very big (up to 145 x 145 x 175 mm on a standard desktop-sized SLA printer).
If precision is an absolute must, you should consider making your lens with an SPDT machine, in which the accuracy is at sub-micron levels.
Conclusion
As it turns out, 3D-printed lenses can be functional. Depending on what you’re using the lens for, it might be the preferred method because of its simplicity and fast turnaround time.
At Jaycon, we have worked with various lenses and can manufacture or prototype them through numerous methods while keeping your application and budget in mind. Get in touch with us today to talk about any optics-related projects and how we can help you achieve your goal.
