A novel fabrication method for high-precision polymer aspherical lenses

Frank C. Wippermann; Jacques W. Duparré; Nico Hagen

doi:10.1117/12.2647728

15 March 2023 A novel fabrication method for high-precision polymer aspherical lenses

Frank C. Wippermann, Jacques W. Duparré, Nico Hagen

Proceedings Volume 12433, Advanced Fabrication Technologies for Micro/Nano Optics and Photonics XVI; 1243308 (2023) https://doi.org/10.1117/12.2647728
Event: SPIE OPTO, 2023, San Francisco, California, United States

Abstract

We have developed a new UV-replication technology for monolithic aspherical polymer lenses. Proprietary process control allows to manufacture lenses with form errors and tolerances suitable for imaging applications, similar to those originating from optical injection molding. However, since UV-replication is carried out at room temperature, in contrast to injection molding, there is a large choice for material selection for the molds and consequently the lens masters can be manufactured much cheaper. With these low initial fabrication costs demonstrators, prototypes, small series and even products in medium volumes of complex imaging systems can now be addressed economically for the first time. Those are otherwise typically limited to spherical glass lenses with all their drawbacks compared to aspheres. Polymer-on-glass UV-replication is well known from wafer level optics. But here the supporting glass wafers remain in the final lens, severely limiting the degrees of freedom of the optical design. In addition, material shrinkage occurring during hardening limits reasonable sag heights of the lenses, so that only low-resolution imaging optics are possible. In our case, the glass substrate in the individual lenses can now be omitted and a full compensation of the shrinkage is achieved with minimum form error. Sag heights of up to 1.8mm and aspherical lens profiles on both sides of thin menisci have already been realized with additional peripheral structures for mechanical self-alignment in materials that even survive reflow-soldering. In this paper we present the benefits of our new technology and the process chain, discuss applied materials and show some demo systems so far realized.

Conference Presentation

Citation Download Citation

Frank C. Wippermann, Jacques W. Duparré, and Nico Hagen "A novel fabrication method for high-precision polymer aspherical lenses", Proc. SPIE 12433, Advanced Fabrication Technologies for Micro/Nano Optics and Photonics XVI, 1243308 (15 March 2023); https://doi.org/10.1117/12.2647728

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