Proceedings Article | 12 August 2010
Proc. SPIE. 7788, Polymer Optics Design, Fabrication, and Materials
KEYWORDS: Optical design, Diamond turning, Photoelasticity, Fluctuations and noise, Polymers, Lens design, Optical fabrication, Projection systems, Aspheric lenses, Heads up displays
This paper investigates the mold design and related effects on an aspheric projector lens for Head Up Display
(HUD) with injection molding process. Injection flow analysis with a commercial software, Moldex3D has been
used to simulate this projector lens for filling, packing, shrinkage, and flow-induced residual stress. This
projector lens contains of variant thickness due to different aspheric design on both surfaces. Defects may be
induced as the melt front from the gate into the cavity with jet-flow phenomenon, short shot, weld line, and even
shrinkage. Thus, this paper performs a gate design to find the significant parameters including injection velocity,
melt temperature, and mold temperature. After simulation by the Moldex3D, gate design for the final assembly
of Head Up Display (HUD) has been obtained and then experimental tests have been proceeded for verification
of short-shot, weight variation, and flow-induced stress. Moreover, warpage analysis of the Head Up Display
(HUD) can be integrated with the optical design specification in future work.
