Iterative aberration compensation of femtosecond 3D-printed microlenses using wavefront measurements

Wavefront compensation provides a highly effective approach for improving the performance of optical elements. In this work, an iterative wavefront-based compensation method for 3D-printed microlenses with diameters up to 630 µm is demonstrated using a phase camera to measure wavefront distortions. The measured wavefront deviations are incorporated into subsequent lens designs, enabling systematic correction of fabrication-induced errors. Through this approach, diffraction-limited performance is achieved for microlenses fabricated on both planar substrates and single-mode fibers, with Strehl ratios up to 0.97 and RMS wavefront errors as low as λ/38 at 638 nm. To evaluate the convergence behavior of the proposed approach, additional microlenses are designed with deliberately introduced spherical aberrations of 0.4 λ and 0.8 λ. For both cases, the presented iterative algorithms achieve Strehl ratios exceeding 0.9 within only two iterations. The wavefront compensation method provides a fast and convenient procedure to optimize the fabrication of 3D-printed optics, particularly for larger optical elements with dimensions greater than 500 µm.