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Glass-glass molding of concave-convex double-sided microlens arrays with high alignment accuracy.

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Title: Glass-glass molding of concave-convex double-sided microlens arrays with high alignment accuracy.
Authors: Zeng, Zihao1 (AUTHOR), Zhou, Tianfeng1,2 (AUTHOR) zhoutf@bit.edu.cn, Zhou, Zhikang2 (AUTHOR), Wang, Gang2 (AUTHOR), Sun, Xiuwen2 (AUTHOR), Yu, Qian2 (AUTHOR), Zhou, Jia3 (AUTHOR), Guo, Yubing1 (AUTHOR)
Source: Precision Engineering. Jun2025, Vol. 94, p80-90. 11p.
Subjects: Finite element method, Coremaking, Optical measurements, Transition temperature, Optical losses
Abstract: The utilization of a double-sided microlens array (DSMLA) eliminates optical energy loss, eliminates assembly errors, simplifies the optical system's structure, and enhances overall performance efficiency. Precision glass molding (PGM) has been applied to fabricate DSMLAs, and the accuracy of aligning the molded DSMLAs significantly impacts optical performance. This study delves into the thermal deformation mechanisms of glass to present a novel approach: utilizing a metal mold core for manufacturing a high transition temperature (T g) glass microlens array (MLA). Subsequently, this high- T g glass MLA is combined with the metal mold core, serving as upper and lower cores, to manufacture low- T g glass concave-convex DSMLAs. The study scrutinizes the impact of optical energy loss rate and alignment errors in concave-convex DSMLAs on optical performance. Moreover, a method to control alignment errors in concave-convex DSMLAs is proposed to boost lens alignment accuracy. A finite element simulation model was established to evaluate the forming speed and stress distribution of the concave-convex DSMLAs. Experimental findings demonstrate that high- T g glass as a mold core facilitates high-precision shape transfer, resulting in concave-convex DSMLAs with high alignment accuracy. Optical measurements reveal that the DSMLAs exhibit excellent beam shaping effects with spot uniformity at 97.23 %. The method provides a strategy for creating concave-convex DSMLAs with high alignment accuracy. • High-Tg glass molds fabricate low-Tg double-sided concave-convex microlens arrays with high alignment accuracy, validated for beam shaping. • Shift/rotation alignment errors reduce spot uniformity/sharpness, impairing beam homogenization. • DSMLAs achieve 97.23% spot uniformity in beam-shaping (optically validated). • Method enables high-precision fabrication of concave-convex DSMLAs. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:The utilization of a double-sided microlens array (DSMLA) eliminates optical energy loss, eliminates assembly errors, simplifies the optical system's structure, and enhances overall performance efficiency. Precision glass molding (PGM) has been applied to fabricate DSMLAs, and the accuracy of aligning the molded DSMLAs significantly impacts optical performance. This study delves into the thermal deformation mechanisms of glass to present a novel approach: utilizing a metal mold core for manufacturing a high transition temperature (T g) glass microlens array (MLA). Subsequently, this high- T g glass MLA is combined with the metal mold core, serving as upper and lower cores, to manufacture low- T g glass concave-convex DSMLAs. The study scrutinizes the impact of optical energy loss rate and alignment errors in concave-convex DSMLAs on optical performance. Moreover, a method to control alignment errors in concave-convex DSMLAs is proposed to boost lens alignment accuracy. A finite element simulation model was established to evaluate the forming speed and stress distribution of the concave-convex DSMLAs. Experimental findings demonstrate that high- T g glass as a mold core facilitates high-precision shape transfer, resulting in concave-convex DSMLAs with high alignment accuracy. Optical measurements reveal that the DSMLAs exhibit excellent beam shaping effects with spot uniformity at 97.23 %. The method provides a strategy for creating concave-convex DSMLAs with high alignment accuracy. • High-Tg glass molds fabricate low-Tg double-sided concave-convex microlens arrays with high alignment accuracy, validated for beam shaping. • Shift/rotation alignment errors reduce spot uniformity/sharpness, impairing beam homogenization. • DSMLAs achieve 97.23% spot uniformity in beam-shaping (optically validated). • Method enables high-precision fabrication of concave-convex DSMLAs. [ABSTRACT FROM AUTHOR]
ISSN:01416359
DOI:10.1016/j.precisioneng.2025.02.014