Abstract
Aspheric micro-lens arrays have been attracting great attention to improve light distribution control. This study proposes a simple and efficient method for fabricating close-packed aspheric micro-lens array. First, silica particles of ϕ10 μm were self-assembled over ϕ10 mm area using sedimentation method. Then the convex profile of the self-assembled particles was replicated to a spherical micro-lens array mold. The mold material was silicone elastomer or polydimethylsiloxane (PDMS). Then, the mold profile was replicated into ultraviolet (UV) curing resin. By applying uniaxial stretching to the mold during the secondary replication, aspheric micro-lens array was fabricated. Deformation of the PDMS mold under uniaxial stretching was analyzed by using finite element analysis (FEA) for rough estimation. Experimental results showed that intended lens profile was obtained though some defects were observed due to the nonuniformity of the particle diameters. Optical characteristic of elliptic micro-lens array was made clear.
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