The low-cost large-scale fabrication of microlens arrays (MLAs) with precise alignment, great uniformity of focusing, and good converging performance are of great importance for integral imaging 3D display. In this work, a simple and effective method for large-scale polymer microlens arrays using screen printing has been successfully presented. The results show that the MLAs possess high-quality surface morphology and excellent optical performances. Furthermore, the microlens' shape and size, i.e., the diameter, the height, and the distance between two adjacent microlenses of the MLAs can be easily controlled by modifying the reflowing time and the size of open apertures of the screen. MLAs with the neighboring microlenses almost tangent can be achieved under suitable size of open apertures of the screen and reflowing time, which can remarkably reduce the color moiré patterns caused by the stray light between the blank areas of the MLAs in the integral imaging 3D display system, exhibiting much better reconstruction performance.

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In this paper, we present a new, to the best of our knowledge, structure of double pinhole/micro-lens array (DP/MLA) with two center-depth planes, used for improving the depth-of-field (DOF) of integral imaging (II), which can be fabricated by a combination of lithography and inkjet printing. The results show that a black circular groove array prepared by lithography can be used for micro-lens location and reduce the stray light for II. By controlling the parameters of the inkjet printing system, DP/MLA with high precision, high alignment, and good focusing ability can be achieved. When the fabricated DP/MLA is applied in the II system, the reconstructed image has a better three-dimensional (3D) image with higher DOF than that by traditional MLA and higher quality than that by ordinary double-layer MLA.

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