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Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
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Adam Morgan ,
Andrew Thomas
Polymers, Volume: 17, Issue: 13, Start page: 1745
Swansea University Authors:
Christian Griffiths, Adam Morgan , Andrew Thomas
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DOI (Published version): 10.3390/polym17131745
Abstract
This paper presents an experimental study of a novel automated manufacturing process that integrates cold embossing to add complex features, such as micro-Fresnel lens designs, onto a 3D-printed ABS polymer component. The research demonstrates that precise control over process parameters, including...
| Published in: | Polymers |
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| ISSN: | 2073-4360 |
| Published: |
MDPI AG
2025
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| Online Access: |
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| URI: | https://cronfa.swan.ac.uk/Record/cronfa69862 |
| Abstract: |
This paper presents an experimental study of a novel automated manufacturing process that integrates cold embossing to add complex features, such as micro-Fresnel lens designs, onto a 3D-printed ABS polymer component. The research demonstrates that precise control over process parameters, including embossing time (Et) and velocity (Ev), is critical for successful feature replication. Gloss analysis confirmed that surface softening as a crucial prerequisite for embossing was successfully achieved using a vapour smoothing (VS) chamber that was developed and optimised for the process. High-speed automation using a 6-axis KUKA robot allowed 48 embosses to be completed in just over one minute, highlighting its efficiency over conventional hot embossing (HE) methods. Results showed that an Et (0.01 s) prevented feature replication as there was insufficient time to allow for polymer flow, while an optimal Et (0.1 s) produced high-quality embosses across all test segments. Additionally, this study identified that while insufficient cycle times hinder polymer flow, extended durations can lead to surface hardening, prohibiting replication. These findings pave the way for integrating Diffractive Optical Elements into 3D-printed parts, potentially enhancing precision, functionality, and productivity beyond the capabilities of standard 3D-printing processes. |
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| Keywords: |
additive manufacturing; automation; cold embossing; diffractive optical lens; vapour smoothing |
| College: |
Faculty of Science and Engineering |
| Funders: |
This research received no external funding. |
| Issue: |
13 |
| Start Page: |
1745 |