Wafer-Level Optics: Scalable Replicated Optical Solutions for OEM Applications Introduction As optical systems continue to shrink in size while increasing in functionality and volume demand, wafer-level optics (WLO) have become a critical enabling technology for OEM applications. By fabricating large numbers of identical......
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......
Thin-Film Coatings on Imprinted Microlens Arrays: Opportunities and Design Considerations 1. Introduction Replicated microlens arrays (MLAs) produced by UV-cured polymer imprinting have become essential in advanced optical assemblies, for collimating, focusing, beam shaping, homogenization, imaging, sensing, and display functions. As these components enter increasingly......
Introduction As optical systems become increasingly integrated at the wafer level, it is often necessary to define where replication polymer should—and should not—exist. Even thin films of polymer in unwanted regions can interfere with electrical contact pads, wafer bonding, or optical interfaces. Holographix’ Selective......
Introduction As optical systems evolve toward wafer-level integration, precise alignment and optical isolation have become central to performance and manufacturability. In this context, chrome patterning, alignment accuracy, and polymer thickness control work together to ensure every replicated microlens array (MLA) performs identically—across thousands of......
Common Sources in MLA Systems: Autofluorescence: See Glossary Surface Scatter: Caused by micro-scale surface roughness or particulate contamination on lens surfaces. Diffraction: As the patterned structures approach the wavelength of light used in the optical system, managing this light becomes more critical. Profile Transitions:......
RoC Tolerancing and Surface Quality Unlike traditional macroscopic lenses, microlens arrays—especially those fabricated via grayscale lithography or precision replication—enable high-fidelity control over arbitrary profiles, whether spherical, aspherical, or freeform. The challenge is not the shape, but the precision and uniformity of that shape. RMS Surface......
Environmental Specifications Parameter Typical Value / Range Notes Operating Temperature −60°C to +180°C (polymer); up to 200°C (glass) Limited by substrate and coating stability Humidity Resistance High for glass; polymers may absorb moisture Protective coatings or encapsulation will mitigate absorption UV Exposure Resistance Excellent......
While every microlens array (MLA) project is custom by nature, tailored to the optical, mechanical, and environmental demands of the end application, Holographix offers the following general specifications as a helpful reference for system designers and engineers. These values represent typical performance targets or standard process capabilities across a wide range of successful MLA programs. ...
Design Importance: Sag height, together with lens diameter and refractive index, determines the focal length and optical power of the microlens. The higher the sag, the greater the lens’s curvature and optical power—but also the more challenging it becomes to fabricate and characterize. Process-Dependent Sag......
Fill Factor and Transition Zones Each microlens in an array needs to blend smoothly into its neighbor. The transition zone is the boundary where the curvature from one lens shape morphs into the next. In this zone, the lens profile no longer follows the intended......
Holographix replicates high-fidelity surface-relief patterns across a remarkable range of scales and formats—from macro optical surfaces to nano-features—so the “types of patterns” we can deliver are as varied as your application. Typical examples include microlens arrays (spherical, aspheric, cylindrical, freeform, micro-Fresnel; square, hex, randomized, or custom tilings), diffraction gratings (binary, blazed, slanted, coarse-pitch to sub-micron), engineered diffusers, diffractive optical elements, and diverse micro-/nano-structures such as pillars, wells, prisms, holes, and textured surfaces. ...
Custom microlens arrays (MLAs) (See MLA Page) are finding their way into an ever increasing number of optical system designs. MLAs can be used in transmission or reflection, providing a valuable new tool for designers of a variety of optical systems....
Developing, prototyping, and manufacturing a diffraction grating involves more than just solving the grating equation Diffraction Grating Equation: mλf=(n)2sinθ Below are important parameters to take into consideration when designing a diffraction grating: Fundamental Grating Parameters Grating Geometry Diffraction Efficiency Stray Light Durability Coatings......
Some materials fluoresce under UV or blue excitation, releasing light at longer wavelengths. This autofluorescence creates a non-coherent, unstructured signal, which can contaminate imaging data—particularly in fluorescence microscopy, biosensing, and quantum applications. Common in: Acrylate-based epoxies Lower-grade polymers Minimized in: Optical-grade silicones UV-stabilized polymers......
Each microlens in an array needs to blend smoothly into its neighbor. The transition zone is the boundary where the curvature.......
Focal length is the distance at which incoming parallel rays converge after passing through the microlens. It’s governed by both the radius of curvature and the refractive index—but strongly influenced by the sag height. For a fixed diameter and material, increasing sag shortens the focal......
Lens diameter refers to the width of each individual microlens. While there’s no absolute physical limit to the diameter, practical design boundaries emerge from optical modeling and fabrication constraints. Lower Bound Considerations: When diameters approach ~10 µm, the system transitions from purely refractive behavior to......
Pitch is the center-to-center distance between adjacent microlenses in an array. It is a key geometric parameter in array layout and plays a significant role in determining the optical fill factor—the proportion of the surface that effectively contributes to light manipulation. Importantly, pitch is not......
RoC defines the curvature of the lens surface and is a key factor in determining focal length and optical power. In microlens arrays, this value is commonly used as a design spec and is typically calculated based on a best-fit curve (usually spherical, unless otherwise......
Sag height is the vertical distance from the base of the microlens to its apex, and is directly related to the lens’s curvature and optical power. It is one of the most critical specifications in microlens array design, both from a performance and fabrication standpoint....
Stray light refers to any light that deviates from its intended optical path and contributes to unintended illumination, glare, background signal, or reduced image contrast within an optical system....