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We demonstrate focusing as well as imaging using diffractive microoptics, manufactured by two-photon polymerization grayscale lithography (2GL), that have been 3D printed into porous silicon oxide. While typical doublet lens systems require support structures that hold the lenses in place, our optics are held by the porous media itself, decreasing both the fabrication time and design constraints while increasing the optically active area. Compared to the typical two-photon polymerization fabrication process, 2GL offers better shape accuracy while simultaneously increasing throughput. To showcase 2GL manufactured optics in porous media, we fabricate singlet diffractive lenses with a diameter of 500 µm and numerical apertures of up to 0.6. We measure the intensity distribution in the focal plane, and along the optical axis. Furthermore, we design and fabricate a doublet lens system for imaging purposes with a diameter of 600 µm and thinner than 60 µm. We examine the imaging performance with a USAF 1951 resolution test chart and determine the resolution to be 287 lp/mm. 3D printing in porous SiO2thus holds great promise for future complex and unconventional microoptical solutions.
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3D Printing of Optical Lenses Assisted by Precision Spin Coating
Abstract Though 3D printing shows potential in fabricating complex optical components rapidly, its poor surface quality and dimensional accuracy render it unqualified for industrial optics applications. The layer steps in the building direction and the pixelated steps on each layer's contour result in inevitable microscale defects on the 3D‐printed surface, far away from the nanoscale roughness required for optics. This paper reports a customized vat photopolymerization‐based lens printing process, integrating unfocused image projection and precision spin coating to solve lateral and vertical stair‐stepping defects. A precision aspherical lens with less than 1 nm surface roughness and 1 µm profile accuracy is demonstrated. The 3D‐printed convex lens achieves a maximum MTF resolution of 347.7 lp mm−1. A mathematical model is established to predict and control the spin coating process on 3D‐printed surfaces precisely. Leveraging this low‐cost yet highly robust and repeatable 3D printing process, the precision fabrication of multi‐scale spherical, aspherical, and axicon lenses are showcased with sizes ranging from 3 to 70 mm using high clear photocuring resins. Additionally, molds are also printed to form multi‐scale PDMS‐based lenses.
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- Award ID(s):
- 2328362
- PAR ID:
- 10508806
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Advanced Functional Materials
- Volume:
- 34
- Issue:
- 44
- ISSN:
- 1616-301X
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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