Continuous Direct-write of a Micro-lens Array or Template Using Dynamic Photomask

Project ID: 1839-AP
Available for licensing

Background

Micro-optics is a key element in the fields of information processing, optoelectronics, and integrated optics. However, existing fabrication methods involve expensive lithographic masks, complicated molding, and reactive ion etching. These methods lack flexibility in geometry and are often limited to low profile micro-optics, which typically do not possess the high numerical aperture required by many applications.

Invention Description

Inventors at The University of Texas at Austin have developed a novel technique and a methodology to fabricate precision micro-optics or their molding templates using a digital micro-mirror or similar device as a dynamic photomask.

The dynamic photomask provides for the substrate and/or the photoreactive resin to continuously translate relative to the image frame. At the same time, the image in the frame shifts in sync with the moving substrate. This method enables the reproduction of micro-scale arrays or repetitive patterns with speed and accuracy.

Benefits

Continuous printing for higher throughput
Complex, precise, high profile micro-optics can be made
Changing geometries can be done "on the fly"
No expensive lithographic masks or replication masters required
Little or no tool contamination and wear
Massively parallel manufacturing

Features

This invention represents a strategy for manufacturing precision micro-optics and templates.
The use of dynamic photomasks offers fast turn-around and the ability to change geometries of printed arrays "on the fly".
This method allows for accomodation of complex and high profile geometries.

Market Potential/Applications

This technology should appeal to the fast-growing digital imaging and optical computing industries which require high-precision, low-cost micro-optics.

IP Status

One U.S. patent application filed

UT Researcher

Shaochen Chen, Ph.D., Mechanical Engineering, The University of Texas at Austin
Yi Lu, Ph.D., The University of Texas at Austin

OTC Contact Information

Les Nichols, Licensing Specialist
lnichols@otc.utexas.edu
512-471-2995