UV-replicated monolithic polymer components towards high-volume applications

Frank C. Wippermann; Jacques W. Duparré; Nico Hagen

doi:10.1117/12.3000732

13 March 2024 UV-replicated monolithic polymer components towards high-volume applications

Frank C. Wippermann, Jacques W. Duparré, Nico Hagen

Proceedings Volume 12898, Advanced Fabrication Technologies for Micro/Nano Optics and Photonics XVII; 128980K (2024) https://doi.org/10.1117/12.3000732
Event: SPIE OPTO, 2024, San Francisco, California, United States

Abstract

UV-replication is well known from wafer level optics, where supporting glass wafers remain in the final lens severely limiting the degrees of freedom of the optical design. In addition, material shrinkage occurring during the curing of the polymer limits reasonable sag heights of the lenses, so that only low-resolution imaging optics are possible. In our UVreplication process, the glass substrate in the individual lenses can now be omitted and a compensation of the shrinkage is achieved with minimum form error. As a result, monolithic components with double-sided aspherical lens profiles of large sag height can be manufactured, as required in high-resolution imaging optics, which previously could only be realized by injection molding. Unlike injection molding, the replication is carried out at room temperature saving large portions of energy required. In combination with a high degree of parallelization as in wafer-level-optics, which is the key to large-scale production, a more environmental-friendly production is possible, since the number of replication machines and thus the required clean room space are significantly reduced. As a further advantage, the used materials meet high temperature requirements and even withstand reflow-soldering performed at 260°C. We present details of our new technology at the example of realized demo systems for 3D-sensing applications using nano-optical structures and imaging use-cases aiming at high-volume, low-cost and high-performance solutions.

Conference Presentation

Citation Download Citation

Frank C. Wippermann, Jacques W. Duparré, and Nico Hagen "UV-replicated monolithic polymer components towards high-volume applications", Proc. SPIE 12898, Advanced Fabrication Technologies for Micro/Nano Optics and Photonics XVII, 128980K (13 March 2024); https://doi.org/10.1117/12.3000732

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