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Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering, 2005., In title on t.p., superscript "TM" follows "S-3DP"., Includes bibliographical references., GRIN lenses with vertical index variation and radial index variation have been successfully fabricated using S-3DPTM. Two silica-based material systems, A1203-SiO₂ and BaO-SiO₂, have been studied and used for the fabrication of GRIN lenses. Aluminum nitrate was dissolved in water to provide the dopant salt solution for S-3DPTM. The pre-sintering treatment at 1000 ⁰Cfor 24 hours in. vacuum (-5x10-6 torr) was used to remove the hydroxyl groups that cause bubbles during sintering. The sintering condition for the A1203-SiO₂ material system was found to be 1650 ⁰C for 30 minutes in vacuum. Two alumina-doped silica GRIN lenses with vertical index variation, Design 1.63 [percent] max and Design 2.5 [percent] max, were fabricated with effective focal lengths of 10.00 cm and 6.10 cm, respectively. An alumina-doped silica GRIN lens with radial parabolic index variation also was fabricated with effective focal lengths of 63.75 cm in the x direction and 52.50 cm in the y direction. The BaO-SiO₂ material system, which has a 2.4 stronger index changing ability than the A1203-SiO₂ material system, also was developed. Barium acetate was used as the dopant source. The pre-sintering treatment was found to be 900 ⁰C for 18 hours in air to convert barium acetate to barium oxide. The sintering condition was found to be 1725 ⁰C for 10 minutes in vacuum. A barium oxide-doped GRIN lens with radial parabolic index variation was fabricated. Its effective focal length was measured to be 14.63 cm in the x direction and 11.14 cm in the y direction. The barium oxide concentration profiles were measured. The theoretical focal lengths were calculated and compared with the effective focal lengths., by Hong-Ren Wang., Ph.D.

The traditional Slurry-based Three-dimensional Printing (S-3DP(TM)) process has been used to fabricate complex structure materials by printing organic binders in selected positions on each printing layer. This process is modified to fabricate functional graded materials, such as gradient index (GRIN) lenses, by depositing different concentrations of dopant at different positions. The modified S-3DP(TM) process offers advantages over conventional GRIN lens processes, including reduced processing time, improved compositional flexibility, and increased index profile dimensionality. Two different approximately parabolic dopant concentration profiles, which have maximum alumina concentrations of 1.63 mol% and 2.50 mol%, are printed into silica powder beds using S-3DP(TM). The samples with maximum alumina concentration of 1.63 mol% have been sintered into optical transparency at 1650 deg. C for 30 minutes in a vacuum furnace (5x10(exp -6) torr) while an additional dehydration process before sintering was required for the samples with maximum alumina concentration of 2.50 mol%. The magnifying effects of GRIN lenses with profiles of 1.63 mol% and 2.50 mol% alumina were observed, yielding effective focal lengths of 10 cm and 6.1 cm, respectively. Light diffraction, which results from the locally inhomogeneous dopant distribution and reduces the optical quality of GRIN lenses, was also observed., This article is from the Mat. Res. Soc. Symp. Proc. Vol. 758 p35-40, 2003. This article is from ADA417756 Materials Research Society Symposium Proceedings, Volume 758 Held in Boston, Massachusetts on December 3-5, 2002. Rapid Prototyping Technologies