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Direct Pattern-to-Curve PDMS-Based Microstructures Fabrication via Thermal Air Expansion for Micro-Optics.

Md Emamul Kabir1, Sonali Garg2, Paras N Prasad2,3

  • 1SMALL (Sensors and MicroActuators Learning Lab), Department of Electrical Engineering, University at Buffalo, The State University of New York at Buffalo (SUNY-Buffalo), Buffalo, New York, USA.

Small (Weinheim an Der Bergstrasse, Germany)
|March 2, 2026
PubMed
Summary
This summary is machine-generated.

Researchers developed a fast, affordable method to create microlens arrays (MLAs) using heated air pressure. This technique simplifies fabrication, making optical-grade lenses accessible for various applications.

Keywords:
compound‐eyecurved microstructuresdirect pattern‐to‐curvedouble castingmicrolens arrays (MLAs)optical transmittancethermal air expansion

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Area of Science:

  • Photonics and optical engineering
  • Materials science and fabrication

Background:

  • Conventional microlens array (MLA) fabrication methods are complex, requiring cleanrooms and expensive equipment.
  • Existing techniques like thermal reflow and grayscale lithography involve multi-step processes, limiting accessibility and scalability.

Purpose of the Study:

  • To introduce a rapid, cost-effective, benchtop fabrication method for microlens arrays (MLAs).
  • To demonstrate the transformation of SU-8/silicon patterns into smooth, curved polydimethylsiloxane (PDMS) MLAs using heated air pressure.

Main Methods:

  • Utilized isotropic heated air pressure to mold SU-8/silicon patterns into PDMS MLAs.
  • Characterized lens surface roughness, focal length tunability, and optical transmittance.
  • Employed a double-casting technique to create convex lens counterparts.

Main Results:

  • Fabricated optical-grade MLAs with low surface roughness (mean values between 1.18 ± 0.48 and 3.3 ± 0.9 nm).
  • Achieved tunable focal lengths from 127.21 to 683.05 µm with 83.06% transmittance for high-curvature patterns.
  • Successfully demonstrated proof-of-concept imaging using both concave-convex arrays and a fabricated compound eye.

Conclusions:

  • The developed method offers a simplified, reproducible, and cost-effective alternative for scalable MLA manufacturing.
  • Reduced equipment complexity and processing time make this technique suitable for broader accessibility.
  • The fabricated MLAs show promising functionality for imaging and photonic applications.