Technology and
Production
Optisches Design
ORAFOL is specialized in the optical design of microstructured surfaces and offers competent support in implementing them.
The implementation is carried out according to specifications described by the customer. Completely new designs are possible as well. For the calculation and simulation specialized software for sequential and non-sequential ray-tracing is used. Every design is optimized for the subsequent tooling process.
Tooling
ORAFOL has long-standing expertise in the manufacturing of specialized tools for the high-precision molding of microstructures.
Essential requirement for the production of high-quality microstructured optics is the precise tooling. Due to decades of experience ORAFOL is capable of manufacturing highly accurate tools for the molding of various types of optics with tight tolerances.
Master tools
The moldings applied in production originate from specialized master tools. These are manufactured in in our in-house tooling center Apolda and replicated within the worldwide ORAFOL corporate network.
Tooling tree
The master tool is the origin for the founding of a tooling tree. In an electro-galvanic process multiple copies of the master are generated in separate generations. For the molding of the polymer optics the stampers are used. With the tooling tree concept the initial master tooling expenses generally only occur once and the production of procuts with consitent quality is secured over decades.
Prototyping
ORAFOL also offers prototyping that bypasses the tooling process. Optical microstructures are cut directly into the polymer allowing for a fast and cost-effective testing before a tooling tree is set-up.
Softtool process
ORAFOL has a specially developed soft tool process for highly complex optics with different structures and large lens arrays. This guarantees that the tools can be manufactured with high precision and efficiency, even for demanding designs.
Precision replication
ORAFOL offers premium quality with high surface quality and trueness to contour as well as tip rounding of only a few micrometers.
Depending on the product the ideal precision replication method is chosen. Large-scale production is possible as well as low quantities.
Various polymers can be used for the production as well as a silicone on glass hybrid (SOG). The one-sided or double-sided replication ís realized in injection stamping, injection molding or compression molding.
Silicone on glass
In a specialized casting process ORAFOL produces microstructured silicone optics on a glass surface (SOG). A thin layer of optical silione is applied and structured according to customer requirements in a wide variety of dimensions.
Product Enhancement
ORAFOL offers a wide spectrum of technologies to enhance optical surfaces.
In order to optimize polymer optics for more demanding applications ORAFOL offers the enhancement of surface parameters in a variety of ways.
The specific characteristisc of the polymer materials are regarded and optimized with vapor depositioning, printing and nanostructuring.
In addition to numerous available standard coatings customer-specific solutions can be developed.
Reflective coating
Development and application of metal coatings to enable or enhance reflective characteristics of polymer surfaces.
Anti-reflective solutions
Interference layer coating
The application of anti-reflective interference layers with thin-film technology can be realized on structured, plano and curved surfaces as well as in combination with hard coating.
Nanostructures
Anti-reflective Nanostructures reduce light reflections on the surface in a wide spectrum.
ORAFOL offers:
- The Motheye-structure is a periodical nanostructure and can be described as an optical grating. It can be applied on plano surfaces by compression molding.
- Our PlasmAR®-nanostructure functions as a graded index layer and is stochastically arranged with different heights and widths of the structure. This irregular arrangement avoids angle depended reflections. The structure can be applied on plano as well as on structured or continuous surfaces.
Hard coating
Application of scratch-resisting hard coating for plano surfaces up to 480 mm in diameter with UV curing coatings in accordance with DIN 52347.
Printing
Finishing
We are able to trim the microstructured products in nearly every shape with tight tolerances.
The trimming of the parts is carried out with CNC technology. It is possible to implement mounting brackets, holes and adjustment aids. High-precision trimming and milling machines enable ORAFOL to realize customer requirements efficiently and accurately. The manufacturing of subassemblies, for example using adhesive processes, is also possible.