Polymer microlens arrays

The manufacture and study of micro-optics has developed into a major topic area as lasers have penetrated telecommunications, information technology and audio-visual services. Microlens arrays can be both high volume and high value articles. After reviewing the topic of microlenses made in both inorganic and plastic materials, this paper describes a new and inexpensive technique of hot pressing for converting a sheet of polymer into one that contains a high quality lens array. The technique is particularly appropriate for lens diameters of about 1-2 mm, where current technologies are either not applicable or prohibitively expensive for trial devices. The optical performance of polycarbonate lens arrays made by this method is compared to presently available moulded plastic lenses of comparable dimensions.