Infrared (IR) optic holds a key element over a broad range of advanced optical systems such as thermal imaging, nightvisions or laser-based sensing. Most infrared optical materials like chalcogenide glasses, however, suffer greattransmission losses due to their high refractive index. Therefore, antireflective (AR) surfaces are necessary to enhance theoptical performance of the IR optics by suppressing undesirable reflection at the optical surfaces and thus increasing thetransmission. The AR-coatings commonly used for IR lenses in the contemporary optic market are expensive andenvironmentally critical. Instead, Precision Glass Molding (PGM), a replicative manufacturing method for the productionof highly precise glass optics, becomes a promising solution to fabricate the AR-nanostructures on the chalcogenide glassesin a cost-efficient manner. The PGM process development starts out a multiscale modeling of the molding process, bywhich the form accuracy of the molded glass lenses is predicted at macroscale while the replication of the AR-structure isvisualized at nanoscale simulation. This simulation necessitates a newly developed thermal-mechanical constitutive modelto represent thermo-viscoelastic behaviors of the chalcogenide glass. Experimental validations of the form accuracy andthe replicated AR-structure of the molded lenses demonstrate essential benefits of the simulation model. This paper focuseson the process simulation as well as the subsequent steps of mold manufacturing and glass molding itself. The success ofmolding AR-structures by precision glass molding promisingly satisfies the increasing demands for the high volumeproduction of inexpensive IR optical elements in today’s optics and photonics markets.
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