Design and fabrication of composite polygonal Fresnel lenses

High fill factor for Fresnel lens arrays has been achieved with the aid of polygonal lenses. This has been done for both circular trimmed lenses and full polygonal lenses, both of which present some optical drawbacks. The composite polygonal Fresnel lens (CPFL) avoids these issues with its unique design - a radial symmetric Fresnel center filling into a polygon, avoiding any intersecting facets within the lens by introducing fillets. To manufacture the CPFL, diamond shaping is applied to not only meet the strict standards required for optical fabrication but also maneuver around the curvilinear features that cannot be fabricated using conventional turning techniques. As such, direct diamond shaping (DDS) was employed to generate an array of CPFLs on a PMMA substrate. Optical simulation was used to validate the performance of the CPFL before production of the lens array, followed by testing of the fabricated lenses, showing less overall noise with better focus compared to conventional polygonal lenses.