Enhancing the micro-LED display uniformity and eliminating dark zones using pixel-coupled micro-lens arrays

This study presents a pixel-lens-coupled micro-lens array (MLA) design to address dark-zone artifacts and non-uniform emission in micro-LED displays. Through LightTools-based optical simulations, the proposed MLA configuration demonstrates effective elimination of dark zones. Systematic analysis of both orthogonal and hexagonal MLA arrangements reveals significant performance improvements compared to bare-pixel configurations. Specifically, the orthogonal MLA achieved an irradiance uniformity of 96.1% (a 123.26% improvement), while the hexagonal MLA reached 94.49% uniformity (a 127% improvement), confirming the design's adaptability for high-density micro-LED applications. Furthermore, a micro-projection system incorporating the optimized orthogonal MLA design was simulated as a viable solution for next-generation micro-display technologies. These results establish a universal framework for display quality improving in high dynamic range and augmented reality applications.