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Summary

This study details the fabrication of polymer microlens arrays for hyperspectral imaging systems using ultraprecision milling and injection compression molding. High-quality microlens arrays were successfully produced with integrated mounting features for seamless system integration.

Keywords:
hyperspectral imaginginjection compression moldingmicrolens arraymicrostructurespolymer opticsultraprecision milling

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Area of Science:

  • Optics and Photonics
  • Materials Science
  • Manufacturing Engineering

Background:

  • Hyperspectral imaging (HSI) systems require high-quality optical components.
  • Fabricating dense microlens arrays (MLAs) presents significant manufacturing challenges.
  • Integration of MLAs into HSI systems necessitates precise mounting features.

Purpose of the Study:

  • To develop and optimize a fabrication process for polymer microlens arrays (MLAs) for HSI systems.
  • To achieve high form accuracy and quality in polymer MLAs.
  • To incorporate design elements for simplified integration into HSI systems.

Main Methods:

  • Ultraprecision milling (UP-milling) with a diamond cutting tool to create the mold insert.
  • Optimization of machining parameters to ensure accuracy and prevent thermal drift.
  • Injection compression molding with a custom tool featuring a moveable frame plate for replication.
  • Characterization of the fabricated MLAs for form accuracy and functionality.

Main Results:

  • Successful fabrication of polymer MLAs with over 12,000 microlenses on a small area (< 2 cm²).
  • Achieved high form accuracy for both the microlenses and integrated mounting features.
  • Demonstrated the functionality of the MLAs within an HSI system, enabling spectral focusing onto a CCD sensor.

Conclusions:

  • The combined UP-milling and injection compression molding process is effective for producing high-quality polymer MLAs for HSI.
  • Optimized process control and custom tooling are crucial for achieving the required precision.
  • The developed MLAs are suitable for integration into HSI systems, validating their optical performance.