This study successfully applied green manufacturing to the fabrication microlens arrays (MLAs) by using grayscale digital masks, defocus methodnewly developed photopolymer in conjunction with digital light processing 3D printing. It is able to rapidly fabricate microlens with high numerical apertures, multiple focal lengths,high fill factor. The MLAs in this study can be applied to image panelssensors,their optical performance are on par with commercial counterparts.

The proposed method combines DLP, new photopolymer, digital grayscale masks,defocus method to mitigate surface roughness challengesmorphological errors. Compared with conventional technologies, the proposed technology has the advantages of short manufacturing time, low material costshigh design flexibility. Meanwhile, it is capable to fabricate microlenses with diameters below 100 µm, resolution higher than 50 lp/mm, numerical aperture over 0.9,fill factor as high as 77.98.

Microlens arrays can be applied to digital cameras, televisions, autostereoscopic 3D displays, light field microscopy camerasMini-LED panels. The technology readiness level of has reached TRL5. Our team are conducting industry-academia collaboration with a startup company,we have also applied for a patent. The short fabrication duration ( 15 minutes), low surface roughness ( 50 lp/mm),low manufacturing costs all make our technique a valuable asset in the market.