LOW-COST PLASTIC SPHERICAL MIRROR

摘要

A method for fabricating a plastic spherical mirror is disclosed. First, a plastic part with a mirror surface supported by a plurality of wall structures is designed. Next, a metal mold including mold for forming the plastic part according the above design specification is provided. A mirror surface of the metal mold is polished to an Al optical grade finish. The metal mold is heated and chilled to form a curvature of the mirror surface of the metal mold. Aplastic material formulation is selected and heated until a melt thereof is obtained. The melt is injected into the mold of the metal mold and the injected melt in the mold is cooled to form the plastic part. A thin layer of a reflective metal coating is deposited on the mirror surface of the plastic part and a protective overcoat is formed on the reflective metal coating.