Forming non-uniform optical guiding structures

摘要

Embodiments are disclosed that relate to casting of an optical part having a non-uniform thickness. For example, one disclosed embodiment provides a method for casting an optical part having a non-uniform thickness, the method including adding a fluid material into a first cavity and into a second cavity separated from the first cavity by a separator. The first and second cavities may each have a non-uniform thickness and the separator may have a configuration complementary to shapes of the first and second cavities such that the first cavity, the second cavity, and the separator form a combined structure having a uniform thickness during a casting process. The method further comprises solidifying the fluid material in the first and second cavities to form the first and second optical parts.

主权项

1. A method for casting a first optical part and a second optical part each having a non-uniform thickness, the method comprising:
adding a fluid material into a first cavity having a movable first casting surface and into a second cavity having a movable second casting surface, the first and second cavities separated by a separator, the first and second cavities each having a non-uniform thickness and the separator having a configuration complementary to shapes of the first and second cavities such that the first cavity, the second cavity, and the separator form a combined structure having a uniform thickness of curable material during a casting process; curing the fluid material in the first and second cavities to form the first and second optical parts; and moving the first casting surface and second casting surface toward the separator during the casting process as the fluid material cures and shrinks.