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Replication of precise polymeric microlens arrays combining ultra-precision diamond ball-end milling and micro injection molding

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Abstract

A simple and novel combination of ultra-precision diamond ball-end milling and micro injection molding technique is described to produce precise microlens arrays out of polycarbonate (PC), polymethylmethacrylate (PMMA) as well as polystyrene (PS). The microlens arrays consist of 100 lenses in a 10 × 10 array with a lens radius of 273 μm, a lens diameter of 300 μm and a lens depth of 45 μm. Pitch between the lenses is fixed at 800 μm. The injection molding parameters were optimized to get precise microlens geometries with low surface roughness. The results show a precise diamond milled mold insert and injection molded microlens arrays with minor deviations in radius and surface roughness of the microlenses, particularly for microlens arrays out of PMMA.

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Acknowledgments

Funding for this work was provided by the National Natural Science Foundation of China (NSFC, reference no. 51050110138).

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Authors and Affiliations

  1. Institute of Polymer Materials and Plastics Engineering, Clausthal University of Technology, Clausthal-Zellerfeld, Germany

    S. Kirchberg, L. Xie & G. Ziegmann

  2. State Key Laboratory of High Performance Complex Manufacturing, School of Mechanical and Electrical Engineering, Central South University, Changsha, China

    L. Chen & B. Jiang

  3. Laboratory for Precision Machining, University of Bremen, Bremen, Germany

    K. Rickens & O. Riemer

Authors
  1. S. Kirchberg
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  2. L. Chen
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  3. L. Xie
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  4. G. Ziegmann
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  5. B. Jiang
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  6. K. Rickens
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  7. O. Riemer
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Correspondence to S. Kirchberg.

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Kirchberg, S., Chen, L., Xie, L. et al. Replication of precise polymeric microlens arrays combining ultra-precision diamond ball-end milling and micro injection molding. Microsyst Technol 18, 459–465 (2012). https://doi.org/10.1007/s00542-011-1414-8

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  • DOI: https://doi.org/10.1007/s00542-011-1414-8

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