Quick-Turn MLA Prototyping
Prototype Microlens Arrays in Less Than 5 Weeks
Overview
Modern LiDAR, datacom, and optical sensing systems demand rapid innovation cycles and early validation of optical architectures. In these applications, microlens arrays (MLAs) play a critical role in beam shaping, illumination control, coupling efficiency, and detector performance. To support aggressive development timelines, Holographix offers a quick-turn MLA prototyping pathway that delivers functional prototype optics in less than five weeksfrom design release.
This accelerated approach enables customers to evaluate real optical hardware early—often well before committing to the cost, time, and risk of a fully populated production master.
Prototype Optics in <5 Weeks
The quick-turn prototyping flow is built around a fast mastering and replication process:
- 2–3 weeks: Rapid fabrication of sample die masters
- ~2 weeks<: Replication, inspection, and delivery
- <5 weeks total: Prototype MLAs ready for system testing
These prototype masters are significantly less expensive than traditional 6″ or 8″ fully populated wafer masters—often a fraction of the cost. This makes them particularly attractive for early-stage development programs where designs are still evolving.
To achieve this speed and cost advantage, certain specifications may be relaxed (for example, tolerance, array size, or feature density). Holographix application engineers work closely with each customer to determine whether the quick-turn path is appropriate and how to best align prototype performance with system-level goals.
Why Customers Choose Quick-Turn Prototyping
Customers in LiDAR, datacom, and optical sensing markets are increasingly drawn to this approach for several reasons:
Fail fast, learn faster
Rather than progressing through lengthy phase-gate processes only to discover late-stage design issues, customers can test real optics early, identify weaknesses, and iterate quickly. This “fail fast” approach often results in lower overall program cost and risk.
Evaluate competing designs in parallel
Because sample die masters are faster and less expensive, multiple MLA designs can be launched simultaneously. Parallel evaluation of optical architectures—different pitches, sags, fill factors, or beam profiles—can dramatically reduce R&D cycles and accelerate convergence on an optimal solution.
Fastest path to system validation
For applications such as:
- LiDAR transmit/receive optics
- VCSEL or laser-diode beam shaping
- Fiber and free-space datacom coupling
- Optical sensing and ranging
early access to prototype MLAs enables rapid validation of optical efficiency, uniformity, alignment tolerance, and system-level performance.
Microlens Arrays and Holographix Capabilities
Holographix specializes in UV-replicated microlens arrays and surface-relief optics, offering:
- Custom MLA design support and application engineering
- Advanced master patterning (including grayscale lithography)
- High-fidelity replication with excellent part-to-part repeatability
- Discrete and wafer-level manufacturing
- Thin-film coatings (AR, reflective, functional)
- Seamless transition from prototype to volume production
Importantly, the same replication technology used for quick-turn prototypes is fully compatible with high-volume manufacturing, ensuring continuity as programs scale.
When Quick-Turn MLAs Are the Right Choice
Quick-turn MLA prototyping is ideal for:
- Early feasibility studies
- Competing optical design evaluations
- Risk reduction prior to full wafer investment
- Programs with aggressive development timelines
Prototype optics in less than five weeks—often the fastest and most economical path to better optical designs.