
- Journal of the European Optical Society-Rapid Publications
- Vol. 20, Issue 1, 2024043 (2024)
Abstract
1 Introduction
The continuous improvements in additive manufacturing (AM), particularly in terms of manufacturing accuracy and surface quality, have led to increased research efforts to utilize it for optical applications [
Nevertheless, optical systems can still benefit significantly from the potential of AM by producing their mounting structures and optomechanical components. So far, AM is commonly used in research and education, with a focus on reprints of existing optomechanical components that need to be readily available, adjustable and of low-cost [
We take advantage of the design freedom of AM to build robust optics that perform well even under harsh environmental conditions. Our approach is to design a fully monolithic mounting structure that supports all elements of the optical system, such as lenses, mirrors, prisms or other optical elements. Firstly, this increases the systems robustness when compared to classical multi-component optomechanics. Secondly, the alignment of the various elements essentially only depends on the accuracy and resolution of the 3D-printer. Finally, the individualization of AM allows to compensate individual element tolerances, such as inner decentration, by adapting the mounting structure accordingly.
In principle, this kind of mounting concept could be realized by using printed mechanical references, like imprinting the optical elements or using fittings as alignment surfaces [
In the following, we describe and discuss our design approach and layout in detail. For the intended proof of concept we designed such a monolithic mounting structure for an imaging lens and produced it from a polyacrylic polymer using a material jetting 3D-printer. Although the material is not ideal for the long term application in mounting structures under harsh conditions, particularly as polymers tend to plastically deform under longer applied mechanical loads due to creeping effects, the manufacturing process is optimal for our purpose. Other usable and commercially available powder bed printers with sufficiently large build volumes for processing more suitable materials, such as aluminium or steel, still have a lower accuracy and more difficult post-processing is required. However, the reason for using this 3D-printer is the transferability of the conceptual proof, obtained from investigations on polymer structures to future structures made of other materials by adapting the spring dimensions. Finally, we evaluate and compare the optical performance of the triplet lens through interferometric measurements with the simulation, both before and after subjecting the entire system to mechanical shock.
2 Fully monolithic and additively manufactured mounting structures
2.1 Mechanical mounting domains of optical elements in optical systems
Optical systems comprise the optical elements and the mounting structure. Optical elements manipulate the light according to system application and specification, usually realized with lenses, mirrors, prisms and filters. The main tasks of the mounting structure are to position the optical elements precisely and provide protection against environmental influences such as pollution, temperature fluctuations and mechanical loads. A mounting structure can be split into two mechanical design domains, the direct and indirect mounting domain, sketched in
Figure 1.Principle cross-sectional sketch of a folded optical system. It comprises the optical elements (blue) and the mounting structure. The mounting structure is split into its two design domains: direct mounting (green) and indirect mounting (grey). Direct mounting is the joining of optical elements and the mounting structure, which determines and fixes their position. Indirect mounting connects those mounted elements and determines their position in relation to each other.
2.2 Basic design of fully monolithic direct mounting structures
Due to its design freedom, AM enables the design and fabrication of mounting structure concepts, which are too complex or even impossible to produce with conventional subtractive manufacturing techniques. Robust optomechanical systems can be designed by combining the direct and indirect mounting domain into one monolithic structure. To provide sufficient clearance during the insertion of optical elements, the structural features that clamp and secure them must be flexible and retractable. Thus, these clamping structures are implemented as spring elements that allow for reversible deformations.
We demonstrate our principle approach with lenses, but it can be easily adapted to all other kinds of optical elements. The force diagram for the fully monolithic mounting concept is shown in
Figure 2.Force diagram to mount lenses in a fully monolithic mount with clamping springs. We sketch our approach in a plane only, but in the full three-dimensional case these structures are preferably arranged with an azimuthal distance of 120. The axial preload
To achieve a higher passive positioning accuracy we have to either reduce the friction or increase the radial forces and thus the radial spring stiffness. The magnitude of the friction force depends on the applied axial preload and the static friction coefficient between the optical element and the mounting structure. The static friction coefficient is a fixed system parameter which is difficult to modify. Thus, the axial preload has to be minimized to such an extent that the lens is just barely but reliably pressed against the mechanical stop. On the other hand, it requires radially stiff springs to accurately align the lens.
The achievable positioning accuracy is calculated according to the force diagram as a function of the axial preload and the radial spring stiffness, as expressed in equation (1):
δpa represents the deflection difference of the radial springs, which remains due to the finite friction forces, and thus it is identical with the positioning accuracy. The minimum required axial preload Fpreload is calculated by multiplying the expected maximum acceleration, resulting from shocks and vibrations during the use of optics in harsh environments, with the mass of the lens. It induces the friction forces between mounting and lens with the static friction coefficient μs. The radial force imbalance has to exceed the resulting friction force, even for small deflections δpa with its radial spring stiffness kradial to accurately position the lens.
Larger accelerations, caused for example by shocks during transport or assembly, are absorbed as elastic deformation by the spring elements and protect the lenses from damage. This results in a temporary displacement of the lens, which is subsequently pushed back by the imbalance of forces. Thus, any displacement is reversed, restoring the optics to full functionality.
The achievable positioning accuracy is plotted as a function of axial preload and radial spring stiffness in
Figure 3.Plot of the positioning accuracy over axial preload and radial spring stiffness. (a) Positioning accuracy with μs = 0.25; (b) Positioning accuracy with μs = 0.5.
2.3 Mechanical implementation of the basic design
To precisely center a lens the radial spring stiffness has to be large to create correspondingly large force differences even for small deflection differences. Additionally, minimizing the axial preload is crucial to ensure minimal friction forces to accurately position the lens. Therefore, it is necessary to have a spring element with two distinct spring stiffnesses in axial and radial direction. In addition, to obtain the required axial preload and the resulting mechanical stresses of this spring element, it is essential to have small deflections to occur in axial and radial direction that ensure a linear deformation behaviour. Thus, it is reasonable to assume that the deflections are almost identical in both directions. The difference in resulting forces between high and low spring stiffness for the same deflection difference is depicted in
Figure 4.Principle graph of resulting force over spring deflection. With the same deflection difference, a low stiffness spring has a smaller difference in its resulting forces than a high stiffness spring.
The lens is inserted into the mount along the axial direction. Once the lens is inserted, it must be held in place by sufficiently large overhangs to prevent its disassembly under large external loads. Thus, along the radial direction a significant deflection range is necessary which is not compatible with the required high radial stiffness, because the bending spring would break. Therefore, a second radial bending spring element is added. It provides the overhangs for retaining the lens in harsh environments and simultaneously allows for enough clearance to insert the lens in the mount.
The mechanical design of a fully monolithic mount is shown in
Figure 5.Sketch of an assembled lens in the monolithic mount with printed spring elements. On the left side is the top down view on the mount. Shown is one of the equally spaced mounting units. On the top right the cross-section along the red dashed line marked with A is depicted. It shows the lens in contact with the direct contacting interface, the cross-section of the positioning spring element (PSE) and its assembly pin. The cross-section along the line marked with B is shown on the bottom right. It shows the retaining spring element (RSE) with its assembly pin in contact with the surface of the lens. Also visible is the mechanical stop on which the PSE tensions the lens.
The PSE generates the radial forces as well as the axial preload to position the lens against the mechanical stop. Achieving a precise axial preload requires accurate deformation of the PSE. For this, the axial length difference between the hook and the mechanical stop in their initial position is used. The hook of the RSE and from the force transmitter prevent a disassembly of the lens in case a large acceleration stresses the system. It should be noted that these interfaces do not affect the positioning of the lens itself, as they are just slightly touch the optical surface and have minimal contact with it.
The assembly process comprises four steps, which are illustrated in
Figure 6.Cross-section view of the assembly process of the lens in the fully monolithic mount. Visible are the PSE (blue), the RSE (green), the lens (light blue), the mechanical stop (grey) and the force transmitter with hook (orange) in the surrounding mounting structure (yellow).
The shape of the bending springs, the magnitude of the forces and stresses are approximated with the Euler–Bernoulli beam theory. Due to its high attainable stiffness and its symmetrical design, we designed the PSE as a fixed beam. The symmetry helps to prevent buckling and twisting effects of the beam and the lens is pushed parallel to the optical axis against the mechanical stop. Since a large clearance for inserting the lens is required, the RSE is implemented as a cantilever bending spring. With other kinds of spring designs it is difficult to achieve high flexibility in one direction as well as high stiffness in the perpendicular direction in a comparatively small design volume.
Because of their large slenderness ratios and their curved design following the lens contour, the design of both spring elements is not optimal for an approximation with the Euler–Bernoulli beam theory. Thus, we performed an additional Finite Element Analysis, confirming that the movement of both spring elements can still be reasonably approximated linear. For the simulation we used the polyacrylic polymer Keyence AR-M2, as it is used to produce the mounting structures. When assembling the lens into the mount, it is important to consider the expected stresses of the PSE to prevent failure, such as breaking. The Von-Mises stress plots of the PSE are in
Figure 7.Plots of the Von-Mises stress from the finite element analysis of the PSE: (a) Von-Mises stress in radial direction; (b) Von-Mises stress in axial direction.
The force applied to the lens by the force transmitter is 10 N. It represents the maximum radial clamping force of the PSE design, considering the highest expected modulus of elasticity of the printing material and variations in the geometry of the spring elements. As a result, the maximum compressive stress beneath the lens surface is 5 N/mm2, caused by Hertzian contact pressure. This is well below the typical compressive stress limit of 345 N/mm2 for optical glass and is therefore not considered critical [
The side view on a demonstrator for this design concept without the RSE is shown in
Figure 8.Side view of a lens mounting structure demonstrator without the RSE. The top shows the mount before lens insertion, while the bottom depicts the lens inserted in the mount. Both depictions are split into simulation (left) and 3D printed model (right). After the lens insertion, the PSE (blue) exhibits an upward deformation and an increased gap between the force transmitter (orange) and the surrounding mounting structure (yellow). For illustrative purposes, the demonstrator was deliberately printed with larger deformations than required for the final design.
2.4 Comparison to other flexure mounts
The presented design concept shares similarities with flexure mounts that use the force equilibrium of their spring elements to reposition the optical elements [
Moreover, the spring elements in our design concept not only ensure the repositioning of the optical elements, but they can also be adjusted to define a certain initial positioning, compensating manufacturing tolerances of the optical elements. In case of lenses typical tolerances are the so called inner decentration, which describes a lateral offset of the first lens surface vertex to the second surface vertex. This can be compensated by accordingly rolling the lens in its mechanical stop. However, this compensation is a multi-step sequential process that requires first to mount the lens, then to measure its positioning or the optical system performance and finally applying the correction with adjustable mechanisms.
Since AM allows to produce individual and very precise structures, mechanical stops defining position of the optical elements can become part of the monolithic mounting structure. This allows to manufacture individual structures in which the mountings for the single lenses are specifically tilted and decentered. These are exactly adjusted to compensate for the inner decentration of the individual lenses that are to be assembled, which can be measured on the unmounted lenses in a preceding step. The range of adjustment is limited by the manufacturing process and not the mounting concept. Thus we only depend on the resolution and accuracy of the 3D printer and not an subsequent assembly or alignment processes of multiple optical and mechanical components.
3 Experimental verification
3.1 Experimental setup and design
The experimental design aims to demonstrate the two key features of our concept. Firstly, we will show that it has a high positioning accuracy and secondly, that it possesses high mechanical robustness. For this we designed and additively manufactured the mounting structure for a triplet lens, according to our concept, and evaluated its optical performance by measuring the wavefront with the Fizeau interferometer VI-direct from Moeller-Wedel Optical. Especially the low order coma aberration is a useful indicator in this regard, as it is zero on axis for a perfectly aligned system. Centration errors in the optical system increase this aberration, which is caused by the misalignment of the lens vertices with the system axis [
The triplet consists of three achromatic lenses, the surface data is shown in
Figure 9.Optical and mechanical design of the triplet: (a) Cross-section of the optical design of the triplet. It consists of three achromatic lenses; (b) Cross-section of the mounting structure. Shown are the three mounts, each with one of their mounting units; (c) Image of the assembled triplet. The lenses are mounted in the 3D-printed mounting structure.
Table Infomation Is Not EnableWe produce the mounting structure with the material jetting 3D-printer Keyence Agilista 3200 using their polyacrylic printing material AR-M2. It has two print heads, one for the model material and one for the support material, which dispenses droplets with a resolution of 40 μm onto its building platform and soldifies them afterwads with an UV-light. Each printing layer has a thickness of 15 μm. The support material is soluble in water and is removed through submersion. After cleaning, the monolithic mounting structures are air-dried at room temperature for three days. Subsequently, the lenses are mounted and then the entire measurement cycle is executed.
The spring elements of the mounting structure are manufactured to attain a positioning accuracy of 6 μm with the design parameters specified in
According to the data sheet, the Young’s modulus of Keyence AR-M2 ranges from 1870 MPa to 2182 MPa. Nevertheless, this variation has hardly any influence on the achievable position accuracy and causes a difference of less than 0.1 μm. Since the resulting forces of the spring element in both axial and radial directions scale linearly with Young’s modulus, only the weight force of the lens is constant. This leads to a slight change in the ratio of the total axial preload, comprising weight force of the lens and the spring forces in the axial direction, to the radial forces.
Typical accelerations during normal handling and usage of optics are assumed to be approximately 3G [
The designed axial preload and therefore the maximum allowable acceleration during usage is 10G. Although this is greater than the desired 3G, it still achieves a positioning accuracy of 6 μm. This results thicker bending springs in the axial direction than necessary, but the disadvantages of a further decrease are not acceptable. Thinner bending springs cause twisting and buckling effects, which compromise the ability to maintain a well-defined axial preload, required for achieving precise element positioning. Moreover, the radial spring stiffness would also be affected negatively by these unwanted twisting and buckling effects, further impacting its functionality. Another approach to circumvent this, are longer spring elements to reduce the axial preload, but they are not feasible due to the restricted available design volume around the lens cylinder to still maintain a compact optical system.
The mechanical shock is applied using a spring system, with the triplet placed in a cage between two vertically arranged springs. The setup and an exemplary acceleration graph is shown in
Figure 10.Acceleration setup to shock the triplet: (a) Image of the shock-test setup. Two springs are vertically arranged with the cage between them, which holds the triplet and acceleration sensor; (b) Exemplary acceleration graph during the shock test.
3.2 Results and discussion
The wavefront of the triplet was measured with the Fizeau interferometer VI-direct from Moeller-Wedel Optical in double pass. The measurement wavelength is 632 nm. The triplet has an aperture of 18.0 mm and a focal length of 61 mm. From this measurement the coma is derived, which is then correlated with the positioning accuracy of the single lenses in the triplet. The results of the sensitivity analysis by means of simulation as well as the experimental measurement results are depicted in
Figure 11.Simulated sensitivity analysis and results of the measurements: (a) Simulated coma of the triplet over a comparable lens decentration (blue line). The coma is evaluated through simulations of the triplet at comparable lens decentrations, achieved by radially misaligning each lens by the same amount simultaneously at a 120-degree angle from one another. The theoretical achievable positioning accuracy of the designed mounting structure is 6.0 μm, which corresponds to a coma value of 0.038, marked with the red dashed line; (b) Measurements of a mounted triplet before, during, and after the application of a continuous external mechanical force on one PSE from the outside to deliberately displace a single lens in the mount; (c) Experimental results of the triplets before and after applying a 15G mechanical shock to them. The plot also includes the calculated achievable positioning accuracy.
The simulated coma of the triplet over the so called comparable lens decentration is shown in
To demonstrate that our design actually repositions decentered elements by itself, we applied a continuous external mechanical load on one of the three PSE to deliberately displace the lens. For this, the triplet was measured before, during and after applying the mechanical load. The results are shown in
Finally, the wavefront of three triplets was measured before and after mechanically shocking them with 15G. The results are shown in
The positioning accuracy, inferred from the wavefront measurements, was better than the predicted 6 μm by the approximation with in equation (1). This can be attributed to several factors. Firstly, the axial forces are slightly lower than their approximation according to the Euler–Bernoulli beam theory, which reduces the resulting friction forces and increases the positioning accuracy. Secondly, measurements of coefficients of friction are inherently dependent on various environmental and operational factors, making them a difficult quantity to measure. This leads to an increase or decrease in the coefficient of static friction, depending on the specific application and environmental conditions. The deviation in the measurement of the static friction coefficient allows a positioning accuracy tolerance of 0.3 μm within our design. Thirdly, the Young’s modulus also exhibits variation, scaling both the axial forces and the radial spring stiffness linearly, while the weight force of the lens remains constant. Hence, the resulting friction through the total axial preload varies slightly. This introduces an additional uncertainty of 0.1 μm. Finally, the comparable lens decentration serves as scenario for comparison. Consequently, the observed coma value represents a limit within the acceptable range to which the optical system alignment is still considered to be within specification.
It is noteworthy that the measured values exhibit a comparatively large distribution, which can be attributed to the alignment of the triplet in the measurement setup. Specifically, the optical axis of the triplet is oriented perpendicular to the plane wave of the interferometer, and even slight deviations of 1 arc minute can result in measurable deviations in the positioning accuracy of 0.5 μm, which can be seen here in the distribution of the measured coma values. This means that we do not measure directly on the optical axis, but slightly besides it.
4 Conclusion and outlook
Through the use of additive manufacturing, a monolithic mounting structure has been developed with a mechanical design that allows for precise positioning and mechanical robustness of multiple mounted optical elements. This was achieved with a monolithic mounting structure design, which is a rigid body without any interfaces between the different components of the mechanical system.
An essential feature of the presented concept is the integration of a system of bending spring elements. They generate a well defined force in axial direction to minimize the resulting friction forces, which hinder an accurate positioning of the optical elements in lateral direction, resulting in a remaining decentration. The friction force is overcome with sufficiently large radial spring stiffnesses, which result in large force differences, even for small remaining deflection differences. Although the design of the monolithic mounting structure has similarities with flexure mounts, it differs significantly in that the deformation of the spring elements is used for the initial positioning of the supported elements and for increasing the mechanical robustness of the entire system.
The system of spring elements also absorbs any mechanical shocks, larger than those specified during its usage, and transforms them into elastic deformation, thus increasing the mechanical robustness of the entire optical system. Since these deformations are reversible, the springs return in their original position and push the mounted elements back in their original position. Moreover, the monolithic design further increases its robustness, in preventing irreversible displacements, which are a concern in conventional multi-component designs. The design is adaptable to meet specific mechanical environmental requirements by adjusting the dimensions of the spring elements. However, the trade-off between positioning accuracy and axial preload, which corresponds expected acceleration during its usage, has to be taken into account.
The measurement results demonstrate the design’s capability to achieve high positioning accuracy and robustness. It reliably positions the lenses initially and repositions them after severe mechanical influences from the environment, such as shocks. This was evaluated by measuring the wavefront’s coma aberration caused by the lens decentrations of a triplet lens, showing that the measurements taken before and after the mechanical shock are almost identical. It was demonstrated that a positioning accuracy better than 6 μm was achieved, which is roughly only 2/10000 of the lens diameter, exceeding the in-plane printer resolution of 40 μm. Consequently, the relative contribution of these remaining lens decentrations on typical overall wavefront errors is very small. Although lenses were used here for demonstration purposes, the design approach can be used for all different kinds of elements that need to be mounted in any type of optical system.
The proof of principle was established using a mounting structure made from a polyacrylic polymer on a material jetting printer. In this design, the spring elements are permanently under tension stress, which causes creep effects and plastic deformation. Therefore, for future applications, other materials with better long-term durability when exposed to constant mechanical loads are preferable. Possible alternatives include metals like aluminium and steel, as well as other polymers such as PEEK or PAI, known for their high creep resistance.
Based on these results, our design approach will enable the production of precise and mechanically stable mounting structures for optical systems that were previously unattainable, thus laying the foundation for new applications in optics. These structures are particularly useful for optical precision instruments that must to operate in harsh environmental conditions. As a result, our design approach can significantly improve the quality and reliability of optical instruments, enable their application in various fields and facilitate the development of advanced and sophisticated optical devices.
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