Glass Molding Process (GMP) is an effective method for producing precise optical elements such as lenses. This simulation study aimed to predict the distribution of temperature and stress within a lens during a multi-stage cooling process of GMP. To develop an accurate simulation model including molds and lens, thermal contact conductance and boundary conditions were determined by analyzing experimental and simulation results. The developed model was used to investigate changes in temperature and maximum principal stress within the lens, considering variations in cooling time, speed, and method at each cooling stage. Simulation results indicated that trends of maximum temperature difference and maximum principal stress within the lens were consistent over time. Results also showed that the maximum principal stress inside the lens increased significantly with additional cooling after uneven temperature distribution caused by a relatively short cooling time. Compared to simulation results of the cooling process involving contact only with bottom surface of the mold, contact cooling with both top and bottom surfaces showed decreased residual stress at the end of cooling and maximum temperature difference within the lens. However, the maximum principal stress could be higher during the cooling process involving both surfaces.

Recent advancements in additive manufacturing (AM) have made it possible to create compact heat exchangers (HXs) with complex geometries. This study introduces a new approach that uses Triply Periodic Minimal Surface (TPMS)-based designs for HXs. Mathematical filtering techniques are incorporated to optimize the local morphology changes. The goal of the proposed mathematical filtering method is to improve the flow characteristics and heat exchange capability of TPMS HXs by modifying the structure’s morphology at the inlet and outlet regions. This modification facilitates flow selection and reduces pressure drop. The HX design includes cylindrical flow domains at the inlet and outlet regions. Three different HX designs with varying inlet/outlet domains (through-hole, half-hole, and taper-hole) were fabricated using polymer AM and DLP 3D printing. These designs were then tested for pressure drop. Among the three designs, the taper-hole configuration showed the best flow characteristics, with a 50% reduction in pressure drop compared to previous studies. The taper-hole design was then replicated using metal AM technology, resulting in a 70-125% improvement in heat exchange capacity compared to previous studies.

The purpose of this study is to propose a better contact surface pattern of a heat radiating block in a progressive GMP (Glass Molding Process) heating assembly. In this study, a simulation model based on FEM was developed to perform a thermal analysis for the heating assembly. It was verified by comparing experimental results. The temperature distribution on the heating block surface and heating energy consumption was analyzed with the change of contact surface pattern and area of a heat radiating block. The considered pattern on the contact surface was cross (+) and straight (-) shape. The contact area ratio was changed from 16 to 100%. The simulation results show that the heating energy consumption increased to reach a target temperature with the increase of contact area ratio. The straight-shaped patterns on a heat radiating block presented more uniform temperature distribution on the mold heating surface than the cross shaped surface, whereas it resulted in a slightly higher energy consumption of up to 9%. This study shows that the contact surface pattern on a heat dissipating block can control the temperature distribution on the mold heating surface.