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A novel hot embossing process to fabricate the hierarchical macro/nano optical glass lens is innovatively proposed. [Display omitted] • A novel hot embossing strategy to fabricate the hierarchical macro/nano optical glass lens is innovatively proposed. • The hierarchical macro-/nano glass lens made by second hot embossing show good optical performance. • The deformation history and forming mechanism of hierarchical macro-/nano glass structures are revealed. Constructing nanostructured surfaces on the macro/micro-scale optical lens is of great importance in the improvement of light transmittance, reflection, and surface functionality of optical devices. In this paper, a flexible and novel material interface design and manufacturing method for hierarchical macro/nano optical glass lenses is proposed. To verify the feasibility of the presented manufacturing strategy, the deformation history and flow driving mechanism of multiscale structured surfaces during second hot embossing were studied by simulations and experiments. The results showed that solid-like glass preform exhibits a higher nanoscale deformation resistance and elastic recovery, which can reduce the distortion levels of the nanostructured surface. At small scales, molecular confinement greatly reduces the tectonic deformation of nanostructured surface at relatively low applied heat and pressure. However, beyond a specific thermal energy threshold, nanostructured convex surfaces are easily compressed into a smooth flattened surface. By collaborative control of embossing conditions, the nano-surface integrity of multiscale structured surface can be ensured during second hot embossing. Compared to the smooth macroscale optical lens, the hierarchical macro/nano glass lens exhibited better optical transmittance and antireflection properties. The proposed design and manufacturing strategy provides a facile and flexible solution for building the hierarchical macro/micro/nanostructure functional optics. [ABSTRACT FROM AUTHOR]

Glass hot embossing is a well-established and cost-effective manufacturing method for glass microstructures. However, the spatial volume affects deformation behaviors in closed mold cavities, which determines the final shape of the embossed glass. To investigate the spatial gas effect on the glass deformation mechanism during hot embossing, we used the focused ion beam (FIB) to fabricate blind micro-hole array structures with different depths as embossing templates. The experimental results demonstrated that the spatial volume of the mold cavity has a great influence on the energy of gas expansion, thus affecting the deformation height of glass microstructures during hot embossing. The deeper the cavity depth, the bigger the surface tension, resulting in larger surface concave deformation. Due to the surface tension of gas expansion, the deformation height of the edge zone is higher than that of the center zone at a higher embossing temperature until the heated glass is completely compressed into the mold cavity. Additionally, at lower embossing temperatures (520 °C), the heated glass has a large deformation resistance and elastic recovery. The more deformation volume escape from the shallower mold cavity because of the spatial effect, thus the deformation height decreases as the cavity depth reduces. The work provides a better understanding of manufacturing glass microstructures in hot embossing. [ABSTRACT FROM AUTHOR]