A comprehensive study was conducted to analyse the quality dependence of a plano-concave molded glass lens on its own dimensions, i.e. the effective diameter, sag ratio, and centre thickness ratio. To achieve this goal, a thermal-displacement coupled finite element analysis was carried out on the whole molding process, in order to get the results of curve deviation, temperature gradient, and residual stress with sets of variations in these dimensions. Then, Taguchi method, one approach for the design of experiments, was incorporated to conduct sensitivity analysis on the simulation results to figure out the dominating sequence of these dimensions. The results show that the effective diameter is the most influential factor amount these three dimensions. In addition, curve deviation is sensitively proportional to diameter and sag ratio, but decreases insignificantly with greater centre thickness ratio.
