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Design and Manufacture of Micro-Optical Lens

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A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "A：Physics".

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 20820

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Special Issue Editors

Prof. Dr. W.B. Lee

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Guest Editor

Partner State Key Laboratory of Ultraprecision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Kowloon, Hong Kong
Interests: advanced materials processing; ultraprecision machining; manufacturing strategy
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Lihua Li

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Guest Editor

Sino-German College of Intelligent Manufacturing, Shenzhen Technology University, Shenzhen 518118, China
Interests: ultra-precision machining technologies and processes; advanced optics design; manufacturing; testing and its applications; development of equipment for ultra-precision machining

Special Issue Information

Dear Colleagues,

A wide range of critical components is used in micro-optics, such as micro-lenses and miniature diffractive and adaptive optical elements in mechatronics products, precision instruments and micromachines. Applications include miniature imaging lens in mobiles, optical fibers, lens for endoscopy and naked eye 3D display, MLA as homogenizers or diffusers, laser beam shaping, etc. The adoption of free-form design further reduces the number of components and renders the optical system more compact and lighter.

Special attention will be paid to glass lenses. Glass is the first material used for optical devices. Advances in polymer optics have dominated the consumer markets in recent decades. The need for higher imaging quality and environmental endurance, together with the advances in manufacturing technology and machine design, lead to the comeback of glass for critical lens applications. The advances in fabrication technology, materials technology, control and automation and the miniaturization of machines have made the automatic production of high precision glass lens accessible to more manufacturers.

We are inviting papers from technology reviews to original and theoretical research works, on all aspects of micro-lens manufacture. These are not limited to molding technology, but also include various fabrication techniques such as precision machining and polishing, rapid prototyping, and lithography, etc.

Prof. Dr. W.B. Lee
Prof. Dr. Lihua Li
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Micromachines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

micro-optics
micro-lens
polymer lens, glass lens
freeform design
miniaturization
control and automation
manufacturing technology
glass molding technology
precision machining
precision polishing
rapid prototyping
lithography

Published Papers (11 papers)

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Research

14 pages, 5158 KiB

Open AccessArticle

The Design of a Fiber-Coupling Micro-Lens Array for an M × N Wavelength-Selective Switch

by Jiaqi Hao, Yunshu Gao, Chengcheng Dong, Zeyuan Meng and Genxiang Chen

Micromachines 2024, 15(3), 307; https://doi.org/10.3390/mi15030307 - 23 Feb 2024

Viewed by 715

Abstract

The M × N port wavelength-selective switch (WSS) is a crucial device used for Reconfigurable Optical Add/Drop Multiplexors and optical switching nodes in optical communication systems. The primary function of an M × N port WSS is to simultaneously transmit and switch multiple input optical signals from input fiber ports to output fiber ports through spatial light coupling. The port array module in a WSS that is responsible for coupling the spatial beam with the fiber determines the important parameters of the M × N port WSS, such as the number of input/output ports and insertion loss. In this paper, VirtualLab Fusion software 2023.1 (Build 1.558), as a powerful physical optics simulation tool, is used to design and optimize a silicon micro-lens array that can achieve the high-precision coupling of a fiber array with a pitch of 1143 μm. Finally, the designed micro-lens is manufactured and experimentally demonstrates its good beam focusing ability with a 3 dB insertion loss. The designed micro-lens array coupling system, which delivers 28 focused spots of approximately 1mm in size (the beam has a

1 / e^{2}

diameter) after transmitting a distance of around 300 mm, effectively extends the number of WSS ports. This design method of the micro-lens array significantly amplifies the port count of the M × N port wavelength-selective switch, effectively expanding it to encompass an impressive 28 × 28 ports. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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14 pages, 5872 KiB

Open AccessArticle

A Study on the Material Removal Characteristics and Damage Mechanism of Lapping for Pressureless Sintered Silicon Carbide (SSiC) Microlens Cavity

by Tianfeng Zhou, Zhongyi Li, Weijia Guo, Peng Liu, Bin Zhao and Xibin Wang

Micromachines 2023, 14(6), 1162; https://doi.org/10.3390/mi14061162 - 31 May 2023

Viewed by 1199

Abstract

Microlens arrays have been widely employed to control the reflection, refraction, and diffraction characteristics of light due to its distinctive surface properties. Precision glass molding (PGM) is the primary method for the mass production of microlens arrays, of which pressureless sintered silicon carbide (SSiC) is a typical mold material due to its excellent wear resistance, high thermal conductivity, high-temperature resistance, and low thermal expansion. However, the high hardness of SSiC makes it hard to be machined, especially for optical mold material that requires good surface quality. The lapping efficiency of SSiC molds is quite low. and the underlying mechanism remains insufficiently explored. In this study, an experimental study has been performed on SSiC. A spherical lapping tool and diamond abrasive slurry have been utilized and various parameters have been carried out to achieve fast material removal. The material removal characteristics and damage mechanism have been illustrated in detail. The findings reveal that the material removal mechanism involves a combination of ploughing, shearing, micro-cutting, and micro-fracturing, which aligns well with the results obtained from finite element method (FEM) simulations. This study serves as preliminary reference for the optimization of the precision machining of SSiC PGM molds with high efficiency and good surface quality. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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14 pages, 3310 KiB

Open AccessArticle

Research on Optical Metrology for Complex Optical Surfaces with Focal Plane Wavefront Sensing

by Xinxue Ma, Jianli Wang, Bin Wang, Xinyue Liu and Yuqiang Chen

Micromachines 2023, 14(6), 1142; https://doi.org/10.3390/mi14061142 - 28 May 2023

Viewed by 1284

Abstract

Complex optical elements have the advantages of improving image quality and optical performance and expanding the field of view. Therefore, it is widely used in X-ray scientific devices, adaptive optical elements, high-energy laser systems, and other fields and is a hot research direction in precision optics. Especially for precision machining, there is a greater need for high-precision testing technology. However, how to measure complex surfaces efficiently and accurately is still an important research topic in optical metrology technology. In order to verify the ability of optical metrology for complex optical surfaces with wavefront sensing based on image information of the focal plane, some experiment platforms in different types of optical surfaces were set up. In order to validate the feasibility and validity of wavefront-sensing technology based on image information of focal planes, a large number of repetitive experiments were carried out. The measurement results with wavefront sensing based on image information of the focal plane were compared with the measurement results with the ZYGO interferometer. The experimental results demonstrate that good agreement is obtained among the error distribution, PV value, and RMS value of the ZYGO interferometer, which shows the feasibility and validity of wavefront sensing based on image information of focal plane technology in optical metrology for the complex optical surface. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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8 pages, 3396 KiB

Open AccessArticle

A Novel Approach for Measurement of Free-Form Optical Elements with Digital Holographic Microscopy

by Xuhui Zhang, Chonglin Wu, Lei Chen, Gengliang Chen and Guoliang Zheng

Micromachines 2022, 13(10), 1719; https://doi.org/10.3390/mi13101719 - 12 Oct 2022

Cited by 1 | Viewed by 1364

Abstract

Free-form optical elements face significant challenges in high-precision measurement due to their high complexity and non-rotational symmetry. Digital holographic microscopy (DHM), as one of the methods for the measurement of free-form optical elements, has promising applications due to its ultra-high precision and non-destructive and fast characteristics. Therefore, we have designed a novel measurement method that combines transmission DHM and reflection DHM to obtain thickness information and surface information of elements to deduce the 3D structure. With this method, we completed the measurement of a free-form optical element. The DHM system we built has recorded holograms under 4× and 20× objectives and successfully recovered the 3D surface shape of the element. The measurements are consistent with the designed and manufactured parameters, demonstrating the unique advantages of DHM for measuring special types of optical elements. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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8 pages, 1816 KiB

Open AccessArticle

Measurement of the Aspherical Optical Surfaces with the Improved Phase Retrieval

by Xinxue Ma, Jianli Wang, Bin Wang and Xinyue Liu

Micromachines 2022, 13(4), 549; https://doi.org/10.3390/mi13040549 - 30 Mar 2022

Cited by 2 | Viewed by 1483

Abstract

In order to verify the estimated wave-front ability of the phase retrieval, a method utilized in the measurement of the aspherical optical surfaces using the phase retrieval technology is described. This technique is based on the algorithm as a solution for the measurement of the aspherical optical surfaces, whose principle is sampling a number of the given defocus images and obtaining the phase information by solving the wave-front with Fourier optical diffractive theory and mathematics optimization. We set up an experimental arrangement used to measure the aspherical optical surfaces using the improved phase retrieval. In addition, we introduced the method of optical alignment in detail, which is very important for high-precision measurements. We obtained an agreement among the error distributions, the peak value, and the root-mean-square value of a ZYGO interferometer, which demonstrates that the improved phase retrieval method can effectively estimate the wave-front and the aberrations of aspherical optical surfaces. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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19 pages, 6257 KiB

Open AccessArticle

Design and Modeling of Fiber-Free Optical MEMS Accelerometer Enabling 3D Measurements

by Samir Abozyd, Abdelrahman Toraya and Noha Gaber

Micromachines 2022, 13(3), 343; https://doi.org/10.3390/mi13030343 - 22 Feb 2022

Cited by 11 | Viewed by 2375

Abstract

Optical accelerometers are popular in some applications because of their better immunity to electromagnetic interference, and they are often more sensitive than other accelerometer types. Optical fibers were employed in most previous generations, making micro-fabrication problematic. The optical accelerometers that are suitable for mass manufacture and previously mentioned in the literature have various problems and are only sensitive in one direction (1D). This study presents a novel optical accelerometer that provides 3D measurements while maintaining simple hybrid fabrication compatible with mass production. The operating concept is based on a power change method that allows for measurements without the need for complex digital signal processing (DSP). Springs hold the proof mass between a light-emitting diode and a quadrant photo-detector, allowing the proof mass to move along three axes. Depending on the magnitude and direction of the acceleration affecting the system, the proof mass moves by a certain amount in the corresponding axis, causing some quadrants of the quadrant detector to receive more light than other quadrants. This article covers the design, implementation, mechanical simulation, and optical modeling of the accelerometer. Several designs have been presented and compared. The best simulated mechanical sensitivity reaches 3.7 μm/G, while the calculated overall sensitivity and resolution of the chosen accelerometer is up to 156 μA/G and 56.2 μG, respectively. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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9 pages, 1224 KiB

Open AccessArticle

Measurement of Small-Slope Free-Form Optical Surfaces with the Modified Phase Retrieval

by Xinxue Ma, Jianli Wang, Bin Wang and Xinyue Liu

Micromachines 2022, 13(1), 82; https://doi.org/10.3390/mi13010082 - 04 Jan 2022

Cited by 3 | Viewed by 1267

Abstract

In this paper, we demonstrate the use of the modified phase retrieval as a method for application in the measurement of small-slope free-form optical surfaces. This technique is a solution for the measurement of small-slope free-form optical surfaces, based on the modified phase retrieval algorithm, whose essence is that only two defocused images are needed to estimate the wave front with an accuracy similar to that of the traditional phase retrieval but with less image capturing and computation time. An experimental arrangement used to measure the small-slope free-form optical surfaces using the modified phase retrieval is described. The results of these experiments demonstrate that the modified phase retrieval method can achieve measurements comparable to those of the standard interferometer. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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14 pages, 3296 KiB

Open AccessArticle

Deformation Analysis of the Glass Preform in the Progress of Precision Glass Molding for Fabricating Chalcogenide Glass Diffractive Optics with the Finite Element Method

by Yue Liu, Yintian Xing, Hang Fu, Chuang Li, Chao Yang, Bo Cao and Changxi Xue

Micromachines 2021, 12(12), 1543; https://doi.org/10.3390/mi12121543 - 11 Dec 2021

Cited by 3 | Viewed by 2547

Abstract

Precision glass molding (PGM) technology is a cost-efficient process for the production of micro/nanostructured glass components with complex surface geometries. The stress distribution, surface profile, and reduced refractive index of the molded lens are based on the lens being fully formed. The process of the deformation of the glass preform is rarely discussed, especially in the case of multi-machining parameters in the experiment. The finite element method (FEM) was adopted to analyze the glass preform deformation. Due to the phenomenon of incomplete deformation of the glass preforms in the experiments, two groups of finite element simulations with different boundary conditions were carried out with MSC.Marc software, to reveal the relationship between the deformation progress and the parameters settings. Based on the simulation results, a glass preform deformation model was established. The error between the model result and the simulation result was less than 0.16. The establishment method of the glass preform deformation model and the established model can be used as a reference in efficiently optimizing PGM processing parameters when the designed lens has two different base radii of curvature. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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Graphical abstract

24 pages, 9654 KiB

Open AccessArticle

Optimum Design of a Composite Optical Receiver by Taguchi and Fuzzy Logic Methods

by Ning Wang, Xing Peng and Lingbao Kong

Micromachines 2021, 12(12), 1434; https://doi.org/10.3390/mi12121434 - 23 Nov 2021

Cited by 5 | Viewed by 1440

Abstract

This paper investigates a composite optical receiver for an indoor visible light communication (VLC) system. The optical gain, received power, and signal-to-noise ratio (SNR) are considered to be optimized. However, it is difficult to find a balance between them in general design and optimization. We propose the Taguchi and fuzzy logic combination method to improve multiple performance characteristics effectively in the optical receiver. The simulated results indicate that the designed receiver has the characteristics of an optical gain of 10.57, a half field of view (HFOV) of 45°, a received power of 6.4635 dBm, a signal-to-noise ratio (SNR) of 89.8874 dB, and a spot size of 2 mm. The appropriate weights of the three performance characteristics for the inputs of the fuzzy controllers increase the optical gain by 13.601 dB, and the received power and SNR by 11.097 dB and 0.373 dB, respectively. Therefore, the optical receiver optimally designed by the Taguchi and fuzzy logic methods can significantly meet the requirements of an indoor VLC system. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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10 pages, 5052 KiB

Open AccessFeature PaperEditor’s ChoiceArticle

A Novel Fabricating Method of Micro Lens-on-Lens Arrays with Two Focal Lengths

by Xin Liu, Min Li, Jiang Bian, Junfeng Du, Bincheng Li and Bin Fan

Micromachines 2021, 12(11), 1372; https://doi.org/10.3390/mi12111372 - 08 Nov 2021

Cited by 5 | Viewed by 2230

Abstract

Micro lens-on-lens array (MLLA) is a novel 3D structure with unique optical properties that cannot be fabricated accurately and quickly by existing processing methods. In this paper, a new fabricating method of MLLAs with two focal lengths is proposed. By introducing the soft lithography technology, nano-imprint technology and mask alignment exposure technology, MLLAs with high precisions can be obtained. A MLLA is successfully fabricated with two focal lengths of 58 μm and 344 μm, and an experiment is carried out. The results show that the MLLA has excellent two-level focusing and imaging abilities. Furthermore, the fabricated profiles of the MLLA agree well with the designed profiles, and the morphology deviation of the MLLA is better than 2%, satisfying the application requirements. The results verify the feasibility and validity of the novel fabricating method. By adjusting mask patterns and processing parameters, MLLAs with both changeable sizes and focal lengths can be obtained. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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16 pages, 7928 KiB

Open AccessArticle

Asymmetric Double Freeform Surface Lens for Integrated LED Automobile Headlamp

by Hui Zhang, Dengfei Liu, Yinwan Wei and Hong Wang

Micromachines 2021, 12(6), 663; https://doi.org/10.3390/mi12060663 - 05 Jun 2021

Cited by 3 | Viewed by 2852

Abstract

We propose a design method of asymmetric double freeform surface lens for an integrated LED automobile headlamp and develop an integrated LED automobile optical system. A single asymmetric double freeform surface lens is designed to redistribute rays emitting from the light source for realizing both low and high beams. Moreover, a freeform surface reflector is used to improve the energy efficiency of high beams. The prism placed in the optical path can suppress chromatic dispersion on the edge of the target plane. Simulation and experimental results show that the illumination values and color temperature of the key points can fully meet the requirements of United Nations Economic Commission for Europe vehicle regulations (ECE) R112, 48, and 128. The volume of the whole optical system comprised of freeform surface elements is smaller than that of the low beam system of a traditional headlamp, resulting in saved space, in which other electronic devices can be installed for the safety of the driver, which indicates that the proposed method is practical in the field of automobile lighting. Full article

(This article belongs to the Special Issue Design and Manufacture of Micro-Optical Lens)

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