Aspheric mirror for head-up display system and methods for forming the same

A method of forming a three-dimensional mirror, the method comprising:

• providing a glass-based mirror preform having a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, the glass preform having a flat shape;
• forming a first chamfer at an edge of the first major surface;
• forming a second chamfer at an edge of the second major surface, the second chamfer having a smaller size than the first chamfer;
• disposing the glass-based preform on a molding apparatus having a curved support surface with the second major surface facing the curved support surface;
• and
• conforming the glass-based preform to the curved support surface to form a curved mirror substrate having a first radius of curvature, wherein, after the conforming, the first major surface has a concave shape and the second major surface has a convex shape.

A heads-up display (HUD) projection system, comprising:

• a display unit configured to display an image to be viewed by a user of a HUD system;
• and
• a mirror configured to reflect the image to a viewing area viewable by the user, the mirror comprising:
• a glass-based substrate having a first major surface that is reflective, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces, and
• a chamfer at an edge of the first major surface, the chamfer having a first length, wherein the second major surface comprises one or more manufacturing artifacts, and
• wherein the manufacturing artifacts are confined to a perimeter region of the second major surface, the perimeter region extending from the edge of the second major surface to a distance that is less than the first length.