TRR 4:  Process Chains for the Replication of Complex Optical Elements

• Subject Area: Mechanical and Industrial Engineering ; Materials Science and Engineering
• Term: from 2001 to 2012
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 5484947

The objective of the new transregional collaborative research centre is to lay the scientific foundations for a deterministic and economical mass production of optical elements with complex geometry. Because of their multiplying effect optics are a key technology that will significantly define industrial competitiveness. Optical products for illumination systems, automotive and aerospace industries, communication technology, and other fields of application are usually manufactured in expensive batch production. The new Transregio aspires to enable a mass production of high-quality optical elements combining and optimizing mold fabrication and replication techniques. Only the combination of these key technologies ensures that complex optical elements such as head-up displays, lightweight camera lenses, concentrators for more effective photo-voltaic elements and also glasses can be produced with higher quality and at lower costs.

• DFG Programme: CRC/Transregios
• International Connection: Denmark, USA

Completed projects

• D01 - Integrated Design of Optical Systems (Project Head Brecher, Christian )
• D02 - Entwicklung neuartiger Spritzgießwerkzeug- und Formteiltechnik für die Abformung hochgenauer Komponenten (Project Head Michaeli, Walter )
• F01 - Ultra-precision milling and grinding techniques for the generation of molds for complex optical elements (Project Head Brinksmeier, Ekkard )
• F02 - Polishing of Large-Scale Curved Surfaces (Project Head Klocke, Fritz )
• F03 - Development of polishing tools and kinematics for polishing of structured opto-functional areas (Project Heads Brinksmeier, Ekkard ;  Riemer, Oltmann )
• F04 - Zonal computer controlled polishing of ultra precision free-form-surfaces (Project Head Brecher, Christian )
• F05 - EDM and ECM Trueing and Dressing of Fine Grained Grinding Wheels (Project Head Klocke, Fritz )
• F06 - Manufacturing of Optical Quality Pyramidal Microcavities by Diamond Micro Chiselling (Project Heads Brinksmeier, Ekkard ;  Gläbe, Ralf )
• F07 - Diamond cutting of nitrocarburized steels for mold inserts (Project Heads Brinksmeier, Ekkard ;  Gläbe, Ralf )
• H01 - Abscheidung neuartiger schleif- und polierbarer Hartstoffschichten für Abformwerkzeuge (Project Heads Stock, Heinz-Rolf ;  Zoch, Hans-Werner )
• H02 - Hard sol-gel coatings by ion irradiation for optical molds (Project Heads Mehner, Andreas ;  Zoch, Hans-Werner )
• H03 - Technologische Grundlagenuntersuchungen zur Bearbeitbarkeit neu-synthetisierter Hartstoffschichten (Project Heads Brinksmeier, Ekkard ;  Preuss, Werner )
• H05 - Production of diamond machinable surface layers of steels by multi-sensor controlled nitrocarburizing processes (Project Heads Hoffmann, Franz ;  Zoch, Hans-Werner )
• M01 - Microtopography characterization of freeform and structured surfaces (Project Head Goch, Gert )
• M02 - Automated form-testing of ultra-precise components in tooling machines (Project Head Schmitt, Robert Heinrich )
• M03 - Non- Destructive Near Surface Analysis (Project Head Goch, Gert )
• M04 - High Resolution Surface Zone Analysis and Ion Beam Processing (Project Head Lucca, Don A. )
• M05 - Quality-oriented planning and improvement of cross-site production process chains (Project Head Schmitt, Robert Heinrich )
• R01 - Development of a system for moulding high precision optical plastics components by integration of adjustable mould inserts in the injection mould (Project Heads Hopmann, Christian ;  Michaeli, Walter )
• R02 - Precision molding of optical components with high form accuracy and surface quality (Project Head Klocke, Fritz )
• T01 - Ultrapräzise Diamantbearbeitung von Stahlformen für die Glas- und Kunststoffabformung (Project Heads Brinksmeier, Ekkard ;  Hoffmann, Franz )
• T02 - Lichtleiter aus Polymeren (Project Head Michaeli, Walter )
• T03 - Entwicklung von Prozessstrategien zur Generierung fehlerfreier Oberflächen bei der Polierbearbeitung von Werkzeugstählen (Project Head Klocke, Fritz )
• T04 - Fertigung großflächiger Anordnungen von Mikroretroreflektoren (Project Head Brinksmeier, Ekkard )
• T05 - Scannende Messung asphärischer Optiken mit hohem Öffnungsverhältnis (Project Head Schmitt, Robert Heinrich )
• T06 - Integration eines kompakten laseroptischen Oberflächen-Messsystems in einen Fertigungsprozess (Project Head Goch, Gert )
• T07 - Abrasive Vibration Polishing (Project Heads Brinksmeier, Ekkard ;  Riemer, Oltmann )
• T08 - Kombinierte Primär- und Vorsatzoptik aus Flüssigsilikonkautschuk für LED-Anwendungen (Project Head Hopmann, Christian )
• Z - Zentrale Aufgaben des SFB/Transregios (Project Head Gläbe, Ralf )

• Applicant Institution: Universität Bremen
• Co-Applicant Institution: Oklahoma State University; Rheinisch-Westfälische Technische Hochschule Aachen
• Spokesperson: Professor Dr.-Ing. Ekkard Brinksmeier