Simple and low-cost polymer lens fabrication using a pressure-driven micro chamber

Area of Science:

• Optics and Materials Science
• Biomedical Engineering
• Additive Manufacturing

Background:

• Traditional lens fabrication can be expensive and time-consuming.
• The development of low-cost, adaptable methods for producing optical components is crucial for advancing healthcare technologies.
• Microfluidic and microfabrication techniques offer potential for novel optical device creation.

Purpose of the Study:

• To present a novel, low-cost method for fabricating various types of lenses.
• To demonstrate the use of a 3D-printed micro chamber for controlling membrane shape.
• To explore the application of this technique in reducing the cost of pilot healthcare devices.

Main Methods:

• Fabrication of a micro chamber using a 3D printer.
• Control of polydimethylsiloxane (PDMS) membrane shape by adjusting internal chamber pressure.
• Casting of ultraviolet-curable resin onto the shaped PDMS membrane.
• Creation of bi-convex, plano-convex, and concave lenses based on chamber pressure and lid geometry.

Main Results:

• Successful fabrication of three distinct lens types (bi-convex, plano-convex, concave).
• Demonstration of pressure-dependent control over membrane curvature and thus lens shape.
• Validation of a cost-effective approach for producing custom optical elements.
• Potential for significant cost reduction in the development of healthcare evaluation devices.

Conclusions:

• The presented 3D-printed micro chamber method offers an accessible and economical route to lens fabrication.
• This technique allows for the precise control of lens geometry through pressure modulation.
• The findings suggest a promising application in the rapid prototyping and cost-effective production of optical components for healthcare services.