Fabrication of polymer micro-lens array with pneumatically diaphragm-driven drop-on-demand inkjet technology

Area of Science:

• Optics and Photonics
• Materials Science
• Microfabrication

Background:

• Micro-lens arrays are crucial components in various optical systems.
• Traditional fabrication methods can be complex and expensive.
• There is a need for scalable and cost-effective micro-lens fabrication techniques.

Purpose of the Study:

• To present an effective method for fabricating micro-lens arrays using ultraviolet-curable polymer.
• To demonstrate the capabilities of a novel pneumatically diaphragm-driven drop-on-demand inkjet system.
• To characterize the optical properties and repeatability of the fabricated micro-lenses.

Main Methods:

• Utilized a custom-built drop-on-demand inkjet system driven by pneumatic diaphragms.
• Employed ultraviolet-curable polymer deposited onto a glass substrate.
• Leveraged surface tension and hydrophobic effects for micro-lens formation.
• Analyzed micro-lens arrays for uniformity, surface quality, and optical performance.

Main Results:

• Successfully fabricated arrays of plano-convex micro-lenses with uniform focusing.
• Achieved smooth surfaces and consistent planar geometry.
• Demonstrated high repeatability with only 1.1% variation in diameter for randomly selected micro-lenses.
• Verified satisfactory focal length, surface roughness, and optical properties.

Conclusions:

• The developed inkjet printing technique is effective for fabricating polymer micro-lens arrays.
• The method offers high flexibility, a simple process, and low production costs.
• This approach shows significant potential for mass production of micro-optical components.