Fabrication of microlens arrays on curved substrates for large viewing angle integral imaging 3D display

Abstract

Curved integral imaging for three-dimensional (3D) displays is well-known for offering an immersive experience and a wider display field of view. Presently, numerous techniques for fabricating curved microlens arrays (curved MLA) have been documented. Nevertheless, the majority of prior research relied on indirect approaches, like utilizing flexible substrates or creating molds. This paper introduces a method for directly fabricating microlens arrays (MLAs) on curved quartz glass. Well-designed arrays of controlled adhesive droplets were created on a hydrophilic-hydrophobic patterned surface. The resulting MLAs, manufactured on a curved substrate with a radius of 10 cm and dimensions of 5 cm × 5 cm, exhibit an 826.5 μm diameter, 56 μm inter-lens spacing, and a 4.5 mm focal length. The effective area of the curved MLA measures 45.8 mm × 45.8 mm. The study encompasses the design of a 2D elemental image and its integration with the curved MLA to achieve a compelling 3D display effect. The lateral viewing range is 2.2 cm. Notably, the field of view angle for the MLA, fabricated on a curved substrate, reached 11.2°, surpassing that of planar MLAs. The imaging system delivers an extensive field of view and attains a realistic 3D stereoscopic display effect. This method, employing various masks, facilitates the rapid fabrication of MLAs on substrates with diverse curvatures and sizes.