High-Throughput Fabrication of Large-Area Optical Glass Microlens Arrays by Roll-to-Plate Hot Embossing

Microlens arrays (MLAs) play an essential role in advanced optical systems, especially in applications such as three-dimensional imaging and augmented reality. However, the mass production of large-area MLAs on optical glass substrates remains challenging due to limitations in replication area and manufacturing efficiency inherent in conventional plate-to-plate (P2P) hot embossing. To enable the fabrication of large-area optical glass MLAs with high efficiency and consistency, this study proposes a novel roll-to-plate (R2P) hot embossing technology designed to achieve high-throughput production while addressing critical challenges in microstructure replication, including embossing-induced surface defects, unsatisfactory forming accuracy, and excessive manufacturing costs for large-area optical microstructures. A combined computational and experimental approach was employed to systematically investigate the glass filling behavior during the R2P embossing process. The parametric effects on MLA filling uniformity were quantitatively evaluated through designed factorial experiments. Optimal processing parameters were subsequently identified, enabling the successful fabrication of glass MLAs with high precision and exceptional surface consistency. This study thus demonstrates R2P hot embossing as a promising and economically attractive solution for the fabrication of advanced glass-based optical systems.