Replication of plastic microlens arrays using electroforming and precision compression molding

Plastic microlens arrays as a popular optical component has been used in wide range of devices because its low cost, high quality, and easy fabrication using simple methods. Although techniques for have advanced considerably recent years, non molding-based methods however are usually not suitable mass production. On the other hand, production rate, but these less capable creating complex components due to restrictions mold making processes. To deal with limitations, process based on electroforming nickel is introduced replicate inserts directly from plastic array, which itself can be fabricated by any flexibility such diamond turning. Then, plated insert precision compression molding, replicated. In this research, proposed method, polymethylmethacrylate (PMMA) array was replicated nickel-plated first another then mass-produced molding process. evaluate suggested properties both arrays, initial were investigated geometrical accuracy, surface performance. The results demonstrated promising technique manufacture rate. By combining method techniques, it possible fill gap between volume demand addition, also fabricate geometries.