In this paper, we introduced a novel microlens array (MLA) design approach with the use of overlapped apertures. The chief ray tracing and paraxial imaging optics are utilised in projection imaging analysis. This work makes MLA structure design requirements more flexible. The proposed design is small and compact. It provides homogeneous illumination over the whole field of view (FOV). In the demonstration, a comparison of the sample 3x3 MLA projector and the proposed 3x3 MLA projector with the same aperture size is illustrated with the help of overlapped apertures. Finally, the proposed MLA projection imaging simulations are accomplished. It substantially outperforms the basic design in terms of FOV and modulation transfer function (MTF). We performed comparative analysis for proposed design with the help of diffraction MTF analysis tool. Our research will aid in the development and exploration of more efficient and advanced compact MLA projection optical systems.
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