Mechanisms and optimization for the rapid fabrication method of polymeric microlens arrays

This paper presents a simple and cost-effective rapid method to make defect-free polymeric microlens arrays at room temperature without applying external pressure. This method uses an optically clear and high-transparency Norland Optical Adhesive (NOA) monomer solution. This is realized by using a combination of a mold and an ultraviolet (UV) polymerization technique. NOA can cross-link in a tenth of a second upon UV exposure. The uniformity and surface quality of the manufactured microlens arrays are investigated through atomic force microscopy and optical microscopy techniques. Experimental results show that the microlens arrays manufactured by the polymerization process are of very high quality without any defects. Further, the surface quality of the lenses can be significantly enhanced by increasing the viscosity of the photosensitive monomer solution.