Method for producing an optical element from plastic

A method for producing an optical element with at least one optically effective surface, wherein the optically effective surface comprises a contour and a surface structure superimposed on the contour, the method at least comprising:

• providing a first injection mold;
• providing a second injection mold configured for forming an optically effective surface comprising the contour and the surface structure superimposed on the contour;
• providing a smooth injection mold configured for forming the contour but not the surface structure superimposed on the contour;
• injecting liquid transparent plastic into the first injection mold to form a first pre-injection molded component depending on a first group of injection molding parameters;
• afterwards cooling the first pre-injection molded component;
• afterwards injection molding a layer of plastic forming an optically effective surface directly or indirectly onto the first pre-injection molded component using the second injection mold and applying a second group of injection molding parameters;
• afterwards substituting the second injection mold by the smooth injection mold;
• injecting liquid transparent plastic into the first injection mold to form a second pre-injection molded component depending on the first group of injection molding parameters;
• afterwards cooling the second pre-injection molded component;
• afterwards injection molding a layer of plastic forming a test-element having an optically effective surface directly or indirectly onto the second pre-injection molded component using the smooth injection mold and applying the second group of injection molding parameters;
• determining optical properties of the test-element;
• depending on the optical properties of the test-element adjusting at least one parameter from the second group of injection molding parameters;
• substituting the smooth injection mold by the second injection mold;
• afterwards injecting liquid transparent plastic into the first injection mold to form a third pre-injection molded component depending on the first group of injection molding parameters;
• afterwards cooling the third pre-injection molded component;
• and
• afterwards injection molding a layer of plastic forming an optically effective surface directly or indirectly onto the third pre-injection molded component using the second injection mold and applying the second group of injection molding parameters with the at least one adjusted parameter.