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Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts

Christian Griffiths, Andrew Rees Orcid Logo, Adam Morgan Orcid Logo, Andrew Thomas Orcid Logo

Polymers, Volume: 17, Issue: 13, Start page: 1745

Swansea University Authors: Christian Griffiths, Adam Morgan Orcid Logo, Andrew Thomas Orcid Logo

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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...

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Published in: Polymers
ISSN: 2073-4360
Published: MDPI AG 2025
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URI: https://cronfa.swan.ac.uk/Record/cronfa69862
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spelling 2025-09-04T13:33:14.4402940 v2 69862 2025-07-02 Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts 84c202c256a2950fbc52314df6ec4914 Christian Griffiths Christian Griffiths true false d6087ed0b26414eea4b519f189cd2fac 0000-0002-3182-7129 Adam Morgan Adam Morgan true false 13d5ed33bce79c052f678401128e4ca1 0000-0002-1942-7050 Andrew Thomas Andrew Thomas true false 2025-07-02 ACEM 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. Journal Article Polymers 17 13 1745 MDPI AG 2073-4360 additive manufacturing; automation; cold embossing; diffractive optical lens; vapour smoothing 24 6 2025 2025-06-24 10.3390/polym17131745 COLLEGE NANME Aerospace, Civil, Electrical, and Mechanical Engineering COLLEGE CODE ACEM Swansea University SU College/Department paid the OA fee This research received no external funding. 2025-09-04T13:33:14.4402940 2025-07-02T09:28:21.2897366 Faculty of Science and Engineering School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering Christian Griffiths 1 Andrew Rees 0000-0003-0455-5444 2 Adam Morgan 0000-0002-3182-7129 3 Andrew Thomas 0000-0002-1942-7050 4 69862__35032__b3de04e9c4c045c4b4f055794ca317a1.pdf 69862.VoR.pdf 2025-09-04T13:31:15.5674815 Output 5394012 application/pdf Version of Record true © 2025 by the authors. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license. true eng https://creativecommons.org/licenses/by/4.0/
title Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
spellingShingle Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
Christian Griffiths
Adam Morgan
Andrew Thomas
title_short Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
title_full Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
title_fullStr Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
title_full_unstemmed Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
title_sort Automated Cold Embossing for the Integration of Optical Lenses onto the Surface of Acrylonitrile Butadiene Styrene (ABS) 3D-Printed Parts
author_id_str_mv 84c202c256a2950fbc52314df6ec4914
d6087ed0b26414eea4b519f189cd2fac
13d5ed33bce79c052f678401128e4ca1
author_id_fullname_str_mv 84c202c256a2950fbc52314df6ec4914_***_Christian Griffiths
d6087ed0b26414eea4b519f189cd2fac_***_Adam Morgan
13d5ed33bce79c052f678401128e4ca1_***_Andrew Thomas
author Christian Griffiths
Adam Morgan
Andrew Thomas
author2 Christian Griffiths
Andrew Rees
Adam Morgan
Andrew Thomas
format Journal article
container_title Polymers
container_volume 17
container_issue 13
container_start_page 1745
publishDate 2025
institution Swansea University
issn 2073-4360
doi_str_mv 10.3390/polym17131745
publisher MDPI AG
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering
document_store_str 1
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description 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.
published_date 2025-06-24T05:25:03Z
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