Microlenses have wide applications for light beam focusing or shaping in microoptical systems. However, it remains challenging for conventional microfabrication methods to rapidly fabricate arrays of microlenses with complex profiles like lens-on-lens structures. In this paper, we present the rapid fabrication of polymer microlenses with lens-on-lens structures by using a digital optical μ-printing technology. An improved dynamic optical exposure method is developed to directly and precisely fabricate polymer top-lensed microlenses (TLMLs). Arrays of TLMLs with either elongated focal depth or two separate foci have been numerically investigated and experimentally demonstrated.
A new optical fabrication technology for fabrication of dual-focus microlens array is presented. We experimentally demonstrated that the surface of microlens can be precisely tailored by the technology to engineer the focal structure of microlens.
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