Additive Manufacturing Based Polymer Compounded Refractive Lenses for X-Ray Focusing at Synchrotron Light Sources

Additive manufacturing offers a promising route to low-cost, rapidly deployable X-ray focusing optics with geometries that are difficult to realize by conventional machining. Here, we report polymer compound refractive lenses (CRLs) for hard X-ray focusing fabricated by projection micro-stereolithography (PµSL, DLP-based) and by two-photon polymerization (2PP). Two-dimensional bi-parabolic CRL elements were produced in multiple photopolymer resins (HTL, Tough, ST1400 for PμSL; IP-S for 2PP) and evaluated by at-wavelength metrology at the Shanghai Synchrotron Radiation Facility. The single-lens residual phase errors (RMS) less than 0.1 λ were measured for PµSL-fabricated HTL, and Toughlenses, respectively, while 2PP-fabricated IP-S lenses achieved 0.008 λ. And the analysis indicates that PµSL lenses are primarily limited by systematic mid-order aberrations, whereas 2PP substantially suppresses coma but shows residual spherical aberration attributable to process calibration and shrinkage. Leveraging the higher fidelity of 2PP, a 65-element parabolic CRL array (radius of curvature of 100 µm) was fabricated and demonstrated hard X-ray focusing at 15 keV with focal spot sizes of 6.4 ± 1 µm (H) and 6.8 ± 1 µm (V), and a flux gain of 220. The measured performance agrees with theoretical expectations when accounting for X-ray source properties, detector resolution and chromatic aberration. These results establish a practical pathway for additively manufactured polymer CRLs with DLP and 2PP techniques as compact, customization focusing optics for synchrotron beamlines.