Plastic reflective waveguide manufacturing

Abstract

A plastic reflective waveguide is manufactured using a soft transfer stamp formed in a first mold using a liquid injection molding process to provide the stamp with parallel wall surfaces having a zero degree draft angle. The soft transfer stamp is placed as an insert in a second mold utilized in a multi-stage thermoplastic injection molding process. A first thermoplastic injection molding stage molds a base part of the plastic reflective waveguide having parallel wall surfaces with a zero degree draft angle. The soft transfer stamp is removed from the second mold and a partially-reflective coating is applied to the base part. A second thermoplastic injection molding stage is utilized to create a secondary part of the plastic reflective waveguide. The raw plastic reflective waveguide is ejected from the second mold and subjected to additional manufacturing processes to realize a finished part meeting design requirements for size and form factor.

Dependencies are inferred from the claim text.