Direct Laser Printing of Tailored Polymeric Microlenses

We report a laser-based approach for the fast fabrication of high-optical-quality polymeric microlenses and microlens arrays with controllable geometry and size. Our strategy consists of the direct laser printing of microdroplets of a highly viscous UV prepolymer at targeted positions, followed by photocuring. We study the morphological characteristics and imaging performance of the microlenses as a function of the substrate and laser parameters and investigate optimal printing conditions and printing mechanisms. We show that the microlens size and focusing properties can be easily tuned by the laser pulse energy, with minimum volumes below 20 fL and focal lengths ranging from 7 to 50 μm.