Page 170 - Chalcogenide Glasses for Infrared Optics

146 Cha pte r S i x

tophat-shaped 17-mm-diameter lens was molded in a metal ring. The
procedure increased the yield of the molding process substantially.
Also, the ring protects the glass from edge fractures.

6.5 Volume Production
From the very start in the molding effort, AMI has been more inter-
ested in producing quality lenses based on the glasses we produce.
We developed molding units and antireflection coatings compati-
ble with chalcogenide glasses. Rapid stamping out of lenses from
chalcogenide glasses was rejected. The AMI molding process uses
low pressure and takes time. There are 5 units installed in the pro-
duction area as shown in Fig. 6.15. All are the same and constructed
here with local help and component parts. The goal here was sim-
ple inexpensive units. With two operators, each unit may be used
twice per day to go through a complete cycle. On that basis, it is
possible the 5 units could produce 10 lenses per day, 50 lenses per
week, or about 2600 lenses per year. To increase production volume
even further, there is enough room in this area to place another 5 or
even 10 units in place. One factor not mentioned is molds and their
cost. The value of the business would have to support the cost of
the new units and the great expense of molds for all the units,
sometimes $10,000 per set.

FIGURE 6.15 Photograph of fi ve AMI molding units in the production area.