During the 1st period, our focus was the following three missions:
1. Choosing the resin for manufacturing the Micro Lens array (MLA) layers of Vision Glass.
2. Find and develop cost-effective alignment tools.
3. Update the system modeling Zemax tool to produce a final specification for the manufacturing Modifying Zemax tool.
Choosing the resin for manufacturing the Micro Lens array (MLA) layers of Vision Glass - Vision Glass is a cutting-edge technology incorporating Micro Lens Arrays (MLA) with distinct High Refraction Index (HRI) and Low Refraction Index (LRI) resins. Our comprehensive analysis of commercially available resins, focusing on critical criteria such as refractive index, clarity, handling complexity, elasticity, curing time, cost, and availability, forms the foundation of our decision-making process.
Integrating a specialized Dynamic Link Library (DLL) with Zemax enhances our ability to optimize Vision Glass system parameters, focusing on improving image quality. Our analysis delves into various resin systems, yielding insights into image quality, optical spot sizes, and ray trace characteristics across radial distances.
Identified promising combinations guide ongoing efforts to fine-tune and advance the Vision Glass system for optimal performance and quality. Three optimized systems perform well, while System 4's inferior performance is attributed to its smaller Delta_n value between High Refraction Index (HRI) and Low Refraction Index (LRI) resins.
Further examination reveals that systems with a higher disparity between HRI and LRI values tend to perform better. Despite this, we opt to initiate film production using parameters from one of the analyzed systems due to our film manufacturer's experience and a desire to minimize risk. Transition to another system may be considered in the future if needed.
Streamline alignment tools: Due to the complex nature of our solution involving Micro-optical elements, precise alignment within specified tolerances is vital during production. While many alignment techniques exist, few meet our accuracy requirements.
Two approaches stand out: one involves marking fiducials on the film for layer alignment and using pressure techniques for seamless matching between layers. This method suits mass production scenarios. Alternatively, a sophisticated approach integrates fiducials with precise illumination and camera systems to detect misalignments and adjust the master dynamically for enhanced precision, ideal for complex production needs.
Currently, we employ illumination and a camera system, with modifications underway to meet our requirements, delayed until June 2024.
Update Zemax modeling tool: Zemax, a renowned optical design software, plays a crucial role in analyzing our Vision-Glass product's performance. Custom modifications, including a Dynamic Link Library (DLL), enable precise simulation and specification of production parameters, overcoming Zemax's standard limitations.
The DLL addresses specific design requirements not supported by Zemax, which are crucial for achieving optimal performance and quality standards for Vision-Glass. These enhancements are pivotal in finalizing production specifications, ensuring our product meets the highest performance and quality standards.
