Replication qualities and optical properties of UV-moulded microlens arrays

UV-moulded microlens arrays with high replication quality were fabricated using a parametric design method. It is important to maximize replication quality because one can obtain replicated micro-optical components with desired properties by accurate control of the shape. In this study, nickel mould inserts for microlens arrays with lenses having diameters between 3 and 230 µm were fabricated by an electroforming process. The reflow method was used to make the master for the metallic mould insert. A UV-moulding system was designed and constructed, and the effects of compression pressure and UV-curing dose on the replication quality of UV-moulded microlens arrays with a diameter of 14 µm were examined experimentally. Finally, geometrical and optical properties of the replicated microlens arrays were measured and analysed.