Injection Molding of Encapsulated Diffractive Optical Elements.

Area of Science:

• Optics and Photonics
• Materials Science
• Manufacturing Engineering

Background:

• Conventional polymer lenses lack advanced functionalities like integrated diffraction.
• Microstructuring techniques offer potential for enhanced optical component performance.
• Hybrid optical systems can combine multiple optical functions in a single component.

Purpose of the Study:

• To present a cost-efficient process chain for creating encapsulated and aligned optical systems with advanced functionality.
• To integrate diffractive optical microstructures into conventional polymer lens systems.
• To demonstrate the production of a zero refractive element using the developed process.

Main Methods:

• Utilizing laser direct writing to structure resist-coated brass substrates.
• Employing electroforming to replicate master structures into nickel plates.
• Integrating diffractive microstructures (height < 0.002 mm) onto polymer lenses within a 30 mm diameter.

Main Results:

• Successful integration of diffractive microstructures into a polymer lens system.
• Precise alignment between lens surfaces and microstructures achieved.
• Demonstration of a functional zero refractive element, validating the process.

Conclusions:

• The presented process chain enables cost-efficient and highly accurate production of complex optical systems.
• This method facilitates the creation of hybrid polymer lenses with integrated alignment and advanced functionalities.
• The technique is suitable for manufacturing sophisticated optical components with enhanced performance.