A New Application of Dynamic Indentation: Indentation Machining Technology

While the indentation method is an excellent way to evaluate the mechanical properties of various sizes of materials, from the nano-scale to the macro-scale, its applications have been limited to measuring mechanical properties. In this study we propose a new application of the dynamic indentation method, in an indentation machining technology for mass-production. The core idea is that the array of residual indentations generated by dynamic indentation testing can be used to fabricate a lens array suitable for thinner and brighter displays. We developed an advanced system from a dynamic indentation system, whose maximum speed and maximum specimen size were about 10Hz and 250 mm*250 mm, respectively. Using dual actuating heads this system was used to produce arrays of lenses having depths of 1 mu m to 6 mm. Pile-up is a critical reason why indentation machining technology had been not widely used in display industries. Since lower pile-up is observed in more ductile copper-based metals, we increased the annealing time of the metal molds to reduce the amount of pile-up. Then, following a quantitative analysis of the annealing heat treatment and resulting amount of pile-up, a lens array was successfully machined on a metal mold fabricated by the developed system. The machined metal mold was used to manufacture optical plates for a lens array. The results verified that the indentation machining technology proposed in this study, based on the dynamic indentation method, can be applied for the manufacturing of optical components for better displays.