Open AccessFabrication of plastic microlens arrays using hybrid extrusion rolling embossing with a metallic cylinder mold fabricated using dry film resist
Author(s) -
Liang-Ting Jiang,
Tseng-Chieng Huang,
Chun-Jung Chiu,
Chih-Yuan Chang,
SenYeu Yang
Publication year - 2007
Publication title -
optics express
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 1.394
H-Index - 271
ISSN - 1094-4087
DOI - 10.1364/oe.15.012088
Subject(s) - materials science , microlens , embossing , photolithography , extrusion , mold , fabrication , polycarbonate , composite material , resist , cylinder , molding (decorative) , optics , optoelectronics , mechanical engineering , lens (geology) , layer (electronics) , medicine , physics , alternative medicine , pathology , engineering
This paper reports a novel and effective method to fabricate microlens arrays on polycarbonate films by hybrid extrusion rolling embossing. The metallic cylinder mold bearing an array of micro-holes is fabricated using photolithography with dry film resist. During the extrusion rolling embossing process, the extruded PC film is immediately pressed against the surface of the roller mold. Under the influence of the rolling pressure and surface tension, an array of convex microlenses is formed. The uniformity and optical properties have been verified. An efficient continuous mass production technique has been demonstrated.