Design optimisation of an optical component used in an endoscopic micro distal end fabricated with two-shot injection moulding

Micro two shot injection moulding is a manufacturing process capable of simultaneously replicating two polymeric parts and assembling them, hence removing the requirement for costly micro assembly. The contribution of this paper consists of a set of findings which emerged from a study carried out to optimise the design of an optical component found in an endoscope micro distal end, fabricated through this process. The case study consists of an optical component and a housing. This paper discloses how the design of the micro optical component was modified so as to avoid weld line formation on the plano-concave lens.