A feasibility study of fabricating self-forming and self-aligned microlens arrays

Microlens array has important applications in array photodetector, display, optical imaging, optical communication and other fields. Aiming at the problems of high production cost, difficult production, tedious coupling alignment steps and difficult to adapt to mass production in the current manufacturing method of microlens array, a method of self-forming microlens array based on the combined action of surface tension and gravity of liquid transparent material is proposed, and the feasibility of whether the method can form microlens array is studied. The theoretical analysis results show that the self-forming microlens array can be formed by the interaction between the surface tension and gravity of the liquid encapsulation medium. The experimental results show that a microlens array with good consistency is formed in the metal mesh array with apertures of 1 mm and 80 μm, which has obvious convergence effect on light.