Bains, N. S., Tan, N. Y. J., Prasad, K. K., Vaishya, R. O., Mishra, V., & Kumar, A. S. (2025). A novel approach to fabricate bicylindrical microlens array using 2-axis ultra-precision machining. Journal of Manufacturing Processes, 151, 1070–1080. https://doi.org/10.1016/j.jmapro.2025.07.067
Abstract:
This paper introduces an innovative approach for ultraprecision machining of microlens arrays using a diamond turning process. The focus is on manufacturing unconventional Steinmetz (Radial-bicylindrical) microlens arrays on a 25 mm × 25 mm surface area. Unlike traditional multi-axis machining approaches, this method employs a two-axis machining platform, ensuring rapid manufacturing of microlens arrays. Using ray tracing simulations, the efficacy of the design was simulated before fabrication. The PMMA microlens array underwent a thorough optical performance validation, confirming the efficacy of the proposed methodology. With a form accuracy deviation of 0.49 μm (∼2 %) in sag, 3.76 μm (>1 %) in profile deviation and a surface finish of 16 nm, this technique demonstrates its potential to quickly produce high-quality microlenses tailored for diverse optical applications. This paper contributes to the advancement of ultraprecision machining in optics, photonics, and sensing applications, offering a novel and straightforward method for manufacturing specialized microlens arrays with superior precision.
License type:
Publisher Copyright
Funding Info:
There was no specific funding for the research done