Fluidic Shaping and Pressure-based Precision Control of Optical Lenses

Fluidic shaping of optical polymer liquids represents an innovative fabrication methodology for optical lens production, enabling rapid in-situ manufacturing of large-aperture space telescope primary mirrors. Ground-based simulation of microgravity conditions for this process can be achieved through density-matching immersion liquids. Current terrestrial fluidic shaping experiments confront significant challenges stemming from density variations during optical polymer material curing. Our study introduces a novel surface profile control technique for optical lens fabrication during density-matched fluidic solidification processes. Through precise regulation of pressure differentials across optical polymer liquid interfaces, the research resolves variable density-matching challenges inherent in polymeric optical materials and achieves convective fluid surface morphology control. A theoretical analysis model correlating surface deformation with applied pressure gradients was established, with experimental validation through comprehensive testing and computational simulations.