PLASTIC REFLECTIVE WAVEGUIDE MANUFACTURING
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United States of America
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Issued Date -
Nov 7, 2024
app pub date -
May 4, 2023
filing date -
May 4, 2023
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Abstract
A plastic reflective waveguide is manufactured using a soft transfer stamp formed in a first mold using a liquid injection molding process to provide the stamp with parallel wall surfaces having a zero degree draft angle. The soft transfer stamp is placed as an insert in a second mold utilized in a multi-stage thermoplastic injection molding process. A first thermoplastic injection molding stage molds a base part of the plastic reflective waveguide having parallel wall surfaces with a zero degree draft angle. The soft transfer stamp is removed from the second mold and a partially-reflective coating is applied to the base part. A second thermoplastic injection molding stage is utilized to create a secondary part of the plastic reflective waveguide. The raw plastic reflective waveguide is ejected from the second mold and subjected to additional manufacturing processes to realize a finished part meeting design requirements for size and form factor.
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