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    This study introduces a novel stacked diffractive optical element (DOE) method. This technique reduces fabrication complexity and cost for multi-level DOEs, achieving performance comparable to traditional methods.

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    Area of Science:

    • Optics and Photonics
    • Diffractive Optical Elements (DOEs)
    • Optical Engineering

    Background:

    • Multi-level DOEs offer wider applications but face challenges in fabrication accuracy and cost.
    • Direct manufacturing of high-level DOEs is complex and expensive.

    Purpose of the Study:

    • To present an improved stacked DOE method for realizing multi-level DOEs.
    • To reduce the manufacturing cost and fabrication difficulty of multi-level DOEs.

    Main Methods:

    • A phase dividing method is employed to decompose a t-level DOE into stacked m-level and n-level DOEs (where t = n × m).
    • The proposed method was demonstrated using a 16-level beam shaping DOE, implemented with 4-level and 4-level (or 2-level and 8-level) stacked DOEs.

    Main Results:

    • Stacked 4x4-level and 2x8-level DOEs achieved a Coefficient of Variation (CV) of 3.69% and 3.58%, respectively, with a diffractive efficiency of 98.11%.
    • Performance metrics are comparable to a single 16-level DOE.
    • Tolerance analysis for horizontal, vertical, and angular displacements of stacked elements was conducted.

    Conclusions:

    • The stacked DOE method simplifies the fabrication of multi-level DOEs.
    • This approach offers a viable solution for cost-effective and less complex manufacturing of advanced optical elements.