Diamond turning and soft lithography processes for liquid tunable lenses

Abstract

Making use of the capability of high precision diamond turning in producing 3-dimensional free form optical surfaces with excellent surface finish, molds for various types of liquid tunable microlenses are fabricated. Subsequently, a rapid prototyping process known as soft lithography is applied to the fabricated mold to replicate multiple lens structures. This method provides an efficient and reliable way of generating rotationally symmetric free form optical surfaces that are otherwise difficult to produce with conventional methods such as lithography and etching methods. Using atomic force microscopy, white light interferometry and a mechanical profiler, it is verified that the surface quality and dimensional accuracy of the replicas are preserved. We demonstrate the practical usefulness of the proposed fabrication methods by developing and experimentally testing three different liquid tunable lenses, namely (1) a diffractive/refractive hybrid lens that reduces chromatic aberration within the visible spectrum, (2) a double focusing lens and (3) an aspherical lens that minimizes spherical aberration. © 2010 IOP Publishing Ltd.