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Manufacturing of a precision 3D microlens array on a steep curved substrate by injection molding process

 
: Zhang, Hao; Scheiding, Sebastian; Li, Lei; Gebhardt, Andreas; Risse, Stefan; Eberhardt, Ramona; Tünnermann, Andreas; Yi, Allen Y.

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Advanced Optical Technologies 2 (2013), Nr.3, S.257-268
ISSN: 2192-8584
ISSN: 2192-8576
Englisch
Zeitschriftenaufsatz
Fraunhofer IOF ()
3D microlens array; 3D micromachining; microinjection molding

Abstract
In this study, a high volume low cost manufacturing method for microoptical microlens arrays on steep curved substrates using a microinjection molding technique was investigated. The design of the individual lenslets was performed using ZEMAX. This 3D microlens array in this study contains 1219 microlenses that are evenly distributed on its concave surface with a high fill factor. The overall field of view of this microlens array on curved substrates is more than 104°. To complete the manufacturing process, first the mold inserts were machined using a voice coil based fast tool servo technique, then the 3D microlens arrays were injection molded. The injection molding process parameters were evaluated using both experiments and numerical simulation for best molding results. In addition, both geometrical errors and optical performance tests showed that the molded polymer microlens arrays can be used in wide angle imaging applications. This study demonstrated that this combined process is capable of fabricating high precision microlens arrays at steep curved substrates at low cost. The microlens arrays created in this study have broad applications in optical, medical and biomedical domains. The success of this study provided a feasible solution for mass production of 3D microlens arrays on arbitrary substrates.

: http://publica.fraunhofer.de/dokumente/N-246815.html