PHABULOuS: manufacturing of large surfaces with free-form micro-optics

Ton Offermans; Frédéric Zanella; Guillaume Basset

doi:10.1117/12.2675845

7 August 2023 PHABULOuS: manufacturing of large surfaces with free-form micro-optics

Ton Offermans, Frédéric Zanella, Guillaume Basset

Proceedings Volume 12624, Digital Optical Technologies 2023; 126240P (2023) https://doi.org/10.1117/12.2675845
Event: SPIE Digital Optical Technologies, 2023, Munich, Germany

Abstract

The need for free-form micro-optics (FFMO) is constantly growing in well-established business segments including flatpanel displays, solid-state illumination, thin-film solutions for security/anti-counterfeiting applications, AR/VR wearables, and automotive headlights. However, the high access barriers to pre-commercial production capabilities prevent companies, especially SMEs, from exploiting the FFMO technology in commercial products and hinder further innovation. To lower the barrier to access FMOA technology, CSEM and their partners have established the PHABULOuS Pilot Line. PHABULOuS offers a unique one-stop shop for all requests for prototyping and manufacturing of free-form microoptics services, from pilot to full-scale production. To mature the FMOA technology, the Pilot Line members have developed high precision origination techniques complemented by industry-fit, high-throughput up-scaling technologies for the cost-effective production of large-area FFMO. At the core of these technologies is Step & Repeat UV imprinting. The method has been successfully demonstrated in the PHABULOuS project for high precision upscaling of rigid small masters to flexible tools with 600 x 300 mm2 dimensions using a standard UV-NIL stepper modified for this purpose. Since there is currently no commercial Step & Repeat machine on the market able to replicate free-form micro-structures on large area with the required precision, CSEM has developed a high precision S&R UV-replication platform designed specifically to this purpose. Combined with the expertise in design and optical simulation, origination, and electroforming, the newly developed Step&Repeat capabilities at CSEM will strengthen the PHABULOuS Pilot Line offerings.

Citation Download Citation

Ton Offermans, Frédéric Zanella, and Guillaume Basset "PHABULOuS: manufacturing of large surfaces with free-form micro-optics", Proc. SPIE 12624, Digital Optical Technologies 2023, 126240P (7 August 2023); https://doi.org/10.1117/12.2675845

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KEYWORDS

Manufacturing

Ultraviolet radiation

Design and modelling

Optics manufacturing

Micro optics

Computer aided design

Optical design

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