Abstract
A simple and rapid method for fabricating semiellipsoid microlens arrays (SEMA) is proposed. An elliptic-array substrate made of resin was first designed and fabricated by twice rollover method with a mold produced by 3D printing. Then droplets of UV curable resin were placed on the elliptic-array substrate and liquid lenses with semiellpsoid shape will be formed due to surface tension. Finally a SEMA can be obtained by curing the liquid lens with UV light. Numerical simulation was employed to predict the stable surface profile, and results show good agreement with the experiments. To massively and rapidly replicate SEMAs, a roll to roll (R2R) imprinting process is proposed,which uses a polydimethylsiloxane (PDMS) mold transferred from the preformed SEMA prototype. Measurements of surface profile are conducted, showing that the relative error of replicated microlens with theoretical is less than 1.59%.
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