Replication of thermoplastic polymer spherical lens array using microforged molding technique

In this paper, we propose a replication method of thermoplastic polymer spherical lens array using a novel microforged mold. The Si₃N₄ ceramic balls, with 3.5 mm diameter, 10 nm surface roughness and 84 nm deviation from spherical profile, were utilized as indentor to generate aluminum alloy lens array mold. Upon the optimization of technical parameters, such as heating and de-molding temperature, indentation force and holding time, a high quality spherical lens array mold was obtained. The mold was used to fabricate spherical PMMA lens array by hot embossing, which showed excellent characteristics on dimensional stability, surface features and optical performances. Especially for the requirements of deep sag height and low f/#, the microforging technique reveals superior performance for low cost and high quality manufacture of spherical lenses. Compared to the previous complicated tools which requires precise calibration, the self-alignment mode of the balls and cavities can easily guarantee positioning accuracy. Accordingly, the pre-milled spherical cavity deformed uniformly in the process of microforging due to the symmetrical distribution of contact pressure and reduced the error caused by deformation. We believe the proposed microforging technique is an ideal mass production approach to the fabrication of thermoplastic polymer spherical lens array.