Optical Components

There are several different effects and uses that clear plastic optical prototypes can be designed for. Basing the component design on the Total Reflection Principle (T.I.R.) to achieve guided light pipes, prisms, and lenses means unlimited applications of the principle.

Using materials with different refractive levels allows a designer to manipulate light using T.I.R. The principle, at the most basic, equals two different levels of refraction meeting at the angle of incidence and the light reflects away. In optical components, refraction and reflection play major roles in the dispersion of light. Like diamonds, the cut determines the direction of the sparkle, the sharper the cut, the more sparkle. The Angle of Incidence is where the Diamond meets air. The Angle of Incidence is why the light seems to bounce off the diamond. T.I.R. is also responsible for the phenomenon that occurs when light bounces off water droplets, better known as Rainbows.

Easy explanation: the light “shifts” or “bounces” off or through an object.

This theory is critical in the engineering of optical components. Certain optical components use different cuts and angles to transport/manipulate the light to the desired location. Without the smooth finish, all the careful designing for the proper impact of light is for nothing. This is why Class A Surface finishes are so critical in the manufacturing of an optical component. Imperfections of any kind can alter the direction of the light, ruining the design that was created solely to optimize the desired level of light manipulation. Aluminum Tooling can easily achieve the Class A surface finish required to create optical components.

AAnother important property of light pipes and light guides is the lack of heat found in other lighting devices. This can be critical in a tight space with low airflow, or in a heat-sensitive area such as a patient whose doctor is using a medical device on them.

Previous to Light pipes / light guides, LED lighting was exclusively used. This was a rather resource-intensive task as each light had to be placed behind the object being back lit. Today the use of Light pipes and light guides is not only cost-effective but practical because the lighting is more consistent throughout the device that needs lighting; and can be used to light up several devices per Light pipe / light guide. Only a few LEDs need to be used and the Light pipe/light guide can efficiently direct the light to the correct device without any loss of intensity.

A prism is based primarily upon the dispersion of light. T.I.R plays a part in this dispersion of light in a prism, creating a sparkle of light. Clear plastic refracts light differently than glass; it separates the colors of the spectrum. Because of the multi-faceted nature of plastics like Acrylic and Polycarbonate (much like a diamond), the reflective qualities make clear plastics use a natural choice in prism lighting design. Most plastic prisms are used in applications that require concentrated and focused light.

A Fresnel Lens is a type of prism. Flat on one side and ridged on the other. Fresnel Lens is constructed of multiple concentric circles to enhance light and image quality rather than focus light like other optical components.

Still reading? Don’t let me lose you as we continue.

You might remember seeing a Fresnel lens way back when. Fresnel lenses were most often used as a portable device to help sharpen the TV screen… Grandma’s big screen Television and the grandkids were the remote control. As old-fashioned as that giant magnifying glass on wheels was… the same technology is being used on giant screen TVs today.

Almost all automobile lenses… taillights, headlights, etc are made of plastic Fresnel Lens made of Polycarbonate or Acrylic due to the durability and strength of both types of plastic. The science behind Fresnel types of lenses is showing up in medical imaging innovations where high resolution, optical quality, lightweight, lack of heat, and cost-efficient production are desirable. In medical applications as well as consumer optical grade Acrylics and Polycarbonates are used. These types of lenses are also being used for overhead projectors, projection TVs, and a multitude of other applications where low cost, low weight, and optical clarity are needed.

Clear plastic lenses are often used in construction products such as laser pointers, construction levels, and surveying devices. Protection devices like face shields and safety glasses also use clear lenses when the safety and strength of the plastic are important to the user’s safety. Clear Plastic Lenses range in applications from consumer goods like sunglasses to various lighting applications from floodlights to flashlights.

Polycarbonate is generally used as an optical lens due to its strength yet flexibility, especially in products for safety or that need to stand up to hard daily usage. Its strength is why it’s often used for safety applications and bulletproof windows. Polycarbonate’s flexibility makes it a natural choice for sunglasses and eyeglasses because Polycarbonate will bend farther than any other plastic of the same thickness. Polycarbonate has a unique blend of flexibility while maintaining strength and optical clarity that no other plastic can match.

Phoenix Proto method follows Scientific Molding principles that are designed not only for success with normally tricky resins but also for cost savings not normally seen with difficult resins coupled with complex designs. Our methods of proper tooling and manufacturing processes are also geared for lean manufacturing for extra cost savings and adhere to our 3-week no-limitation concept to parts Aluminum Tooling.

Acrylics have excellent transparency, optical clarity, and hardness which are all desirable qualities in lenses, prisms, and other light-guiding optical applications. Acrylic is often used instead of glass due to Acrylic’s ability to refract light and filter the light according to a design based on the Total Reflection Principle and the Angle of Incidence.

The Acrylic family of resins is very heat resistant which makes it a somewhat difficult plastic to run for desirable applications. When run correctly, acrylic plastic properties are attractive to design engineers due to Acrylic’s very versatile nature and a practical choice for decorative plastic manufacturing.

Clear Polycarbonate is preferred due to its high optical transparency that allows for complete light reflection. High optical transparency makes clear Polycarbonate a natural choice for Light pipes, light guides, and optical lenses. The impact resistance and heat resistance qualities make Polycarbonate especially favorable to consumer and medical applications. Adding that there are medical grade ISO 10993-1 and USP Class VI standard Polycarbonate makes it even more useful to medical applications requiring such plastic types.

Prototype molders generally do not favor Clear Polycarbonate due to its high mold temperatures. To create desirable parts the temperature must remain at a constant to flow properly and overcome its inherent nature. In rapid injection molding is a level of difficulty that often cannot be turned into an efficient enough process for quick turnaround parts.

The Phoenix Proto method is uniquely suited for creating optical components, quickly, efficiently, and correctly.