Fabrication of Micro-Lens Array by Replication of Self-Assembled Particles Profiles and Application of Mold Deformation to Obtain Aspheric Lens Array

Aspheric micro-lens arrays have been attracting great attention to improve light distribution control. This study proposes a simple and efficient method for fabricating close-packed aspheric array. First, silica particles of ϕ10 μm were self-assembled over mm area using sedimentation method. Then the convex profile was replicated spherical array mold. The mold material silicone elastomer or polydimethylsiloxane (PDMS). Then, into ultraviolet (UV) curing resin. By applying uniaxial stretching during secondary replication, fabricated. Deformation PDMS under analyzed by finite element analysis (FEA) rough estimation. Experimental results showed that intended lens obtained though some defects observed due nonuniformity particle diameters. Optical characteristic elliptic made clear.