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Efficient engineering and design
Aixtooling GmbH is your innovative, flexible engineering and design partner for precision molded glass optics.

Based on extensive competence in all important components of the process chain, we can tune our tool design flexibly to your needs. For example, the glass molding process is simulated by finite element methods (FEM), significantly reducing the iteration costs of the subsequent tool making.

We meet your specific requirements during tool design, taking the anticipated production volume into consideration. We also adapt the optic design to the fabrication processes of precision molding.

Procedure during design and development
FEM Simulation des Pressens einer Plan-Konvex Linse
FEM Simulation
FEM-Analyse

We work out an optimum tool design using the finite element method (FEM)

In many cases, Aixtooling is capable of carrying out a process qualification for precision molding based on an existing optic design. The first step in these cases is a close coordination or cooperation with the optic designer. At the same time, it is a good idea to change individual contour elements in the classical lens design in order to improve the moldability of the optic. A change in glass type can also be discussed, if alternative glasses with better molding behavior and similar optical characteristics are available.

After the optical design is determined, the tool design phase starts. In many cases, a finite element simulation (FEM) of the molding task is carried out in parallel with this phase. However, this presumes that there is sufficient data regarding the temperature-dependent material characteristics of the glass types selected. The power of the FEM supports the design process at several points. First, the shrinking behavior of the glass during cooling can be predicted. This permits form deviations in the lens to be taken into consideration in the tool design right from the start. However, the FEM also provides information about mold filling behavior, permitting an optimized design. The simulation of tension evolution within molded lenses highlights critical points and also helps improve the design.

Design development especially includes the design and detailing of the tool systems. The use of multiple tools can significantly increase the productivity per pressing cycle. The construction of multiple tool systems, however, is more complex, requiring sophisticated tolerance management in order to meet the lens specifications of all the individual lenses. The correct choice of material for different tool components also plays a decisive role here, particularly regarding heat expansion behavior.

Compensation for form deviation after molding
Im Rahmen der Prozessqualifizierung für eine neue Linse ist eine schnelle Designentwicklung notwendig. Aixtooling setzt hier auf modulare und standardisierte Werkzeugkonzepte.
Werkzeugdesignentwicklung

In the context of a process qualification, an iteration of the process chain to optimize form precision is usual.

After the first iteration of molding, in many cases a deviation of the lens geometry from the planned design can be detected. This is generally due to the strict requirements for form precision in replicative optics.

Based on the contour information or data received, Aixtooling is capable of making appropriate tool corrections. For this purpose, the measurement data must first be subjected to a precise target/actual comparison. The data is then prepared and returned to the process chain in suitable form. That is, a new target tool contour is generated.

The optical properties of glass can also change due to the hot molding process. Based on the refractive index, the term "index drop" is often used. If the index drop is not already known based on available data, there can be a process qualification phase to measure it. If the index drop is already known, it can be taken into consideration during the next press iteration using an appropriate adaptation of the optical design.

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© 2009 Aixtooling GmbH
Steinbachstraße 17, 52074 Aachen, Deutschland
Phone +49 241 8904-499
Fax +49 241 8904-6499
E-Mail: info@aixtooling.de
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