In Situ Electrohydrodynamic Jet Printing-Based Fabrication of Tunable Microlens Arrays

Investigation into fabrication and optical characteristics of tunable optofluidic microlenses using two-photon polymerization

Optofluidic systems, integrating microfluidic and micro-optical technologies, have emerged as transformative tools for various applications, from molecular detection to flow cytometry. However, existing optofluidic microlenses often rely on external forces for tunability, hindering seamless integration into systems. This work presents an approach using two-photon polymerization (TPP) to fabricate inherently tunable microlens arrays, eliminating the need for supplementary equipment. The optofluidic design incorporates a three-layered structure enabling dynamic manipulation of refractive indices within microchannels, leading to tunable focusing characteristics. It is shown that the TPP fabricated optofluidic microlenses exhibit inherent tunable focal lengths, numerical apertures, and spot sizes without reliance on external forces. This work signifies some advancements in optofluidic technology, offering precise and tunable microlenses with potential applications in adaptive imaging and variable focal length microscopy.

Free-Boundary Microfluidic Platform for Advanced Materials Manufacturing and Applications

Microfluidics, with its remarkable capacity to manipulate fluids and droplets at the microscale, has emerged as a powerful platform in numerous fields. In contrast to conventional closed microchannel microfluidic systems, free-boundary microfluidic manufacturing (FBMM) processes continuous precursor fluids into jets or droplets in a relatively spacious environment. FBMM is highly regarded for its superior flexibility, stability, economy, usability, and versatility in the manufacturing of advanced materials and architectures. In this review, a comprehensive overview of recent advancements in FBMM is provided, encompassing technical principles, advanced material manufacturing, and their applications. FBMM is categorized based on the foundational mechanisms, primarily comprising hydrodynamics, interface effects, acoustics, and electrohydrodynamic. The processes and mechanisms of fluid manipulation are thoroughly discussed. Additionally, the manufacturing of advanced materials in various dimensions ranging from zero-dimensional to three-dimensional, as well as their diverse applications in material science, biomedical engineering, and engineering are presented. Finally, current progress is summarized and future challenges are prospected. Overall, this review highlights the significant potential of FBMM as a powerful tool for advanced materials manufacturing and its wide-ranging applications.

Superhydrophobic Multifocal Microlens Array with Depth-of-Field Detection for a Humid Environment

Microlens array (MLA) has been widely applied in augmented reality and optical imaging. When used in a humid environment or medical endoscopy, MLA needs to be both superhydrophobic and multifocal. However, it is not easy to achieve both superhydrophobic and multifocal function by integrating superhydrophobic and multifocal structures on the same surface by means of a simple, efficient, and precise method. In this paper, the superhydrophobic multifocal MLA with superhydrophobic properties and multifocal functions is successfully designed for preparation based on a method of 3D lithography and soft lithography. The 3D lithography can further help the preparation of a multifocal MLA with varying apertures and a multistep superhydrophobic structure with a round dome. The superhydrophobic multifocal MLA with periods 50 and 120 μm has perfect superhydrophobic property. The water droplet can slide and bounce off the surface at a roll angle of less than 12.9° with both multifocal and integrated imaging function, as well as up to 397 μm depth-of-field (DOF) detection range; this greatly exceeds the conventional MLA. The perfect superhydrophobic and optical property can be achieved in an extremely humid environment. The superhydrophobic multifocal MLA proposed in this paper has a promising prospect for actual practices.

Development of Shape Prediction Model of Microlens Fabricated via Diffuser-Assisted Photolithography

The fabrication of microlens arrays (MLAs) using diffuser-assisted photolithography (DPL) has garnered substantial recent interest owing to the exceptional capabilities of DPL in adjusting the size and shape, achieving high fill factors, enhancing productivity, and ensuring excellent reproducibility. The inherent unpredictability of light interactions within the diffuser poses challenges in accurately forecasting the final shape and dimensions of microlenses in the DPL process. Herein, we introduce a comprehensive theoretical model to forecast microlens shapes in response to varying exposure doses within a DPL framework. We establish a robust MLA fabrication method aligned with conventional DPL techniques to enable precise shape modulation. By calibrating the exposure doses meticulously, we generate diverse MLA configurations, each with a distinct shape and size. Subsequently, by utilizing the experimentally acquired data encompassing parameters such as height, radius of curvature, and angles, we develop highly precise theoretical prediction models, achieving R-squared values exceeding 95%. The subsequent validation of our model encompasses the accurate prediction of microlens shapes under specific exposure doses. The verification results exhibit average error rates of approximately 2.328%, 7.45%, and 3.16% for the height, radius of curvature, and contact angle models, respectively, all of which were well below the 10% threshold.

Novel Optofluidic Imaging System Integrated with Tunable Microlens Arrays

Optofluidic tunable microlens arrays (MLAs) can manipulate and control light propagation using fluids. Lately, their applicability to miniature lab-on-a-chip systems is being extensively researched. However, it is difficult to incorporate 3D MLAs directly in a narrow microfluidic channel using common techniques. This has resulted in limited research on variable focal length imaging with optofluidic 3D MLAs. In this paper, we propose a method for fabricating MLAs in polydimethylsiloxane (PDMS)-based microchannels via electrohydrodynamic jet (E-jet) printing to achieve optofluidic tunable MLAs. Using this method, MLAs of diameters 15 to 80 μm can be fabricated in microfluidic channels with widths of 200 and 300 μm. By alternately using solutions with different refractive indices in the microchannel, the optofluidic microlenses exhibit reversible modulation properties while retaining the morphologies and refractive indices of the microlenses. The focal length of the resulting optofluidic chip can have threefold tunability, thereby achieving an imaging depth of approximately 450 μm. This outstanding advantage is useful in observing microspheres and cells flowing in the microfluidic system. Thus, the proposed optofluidic chip exhibits great potential for cell counting and imaging applications.

Analysis and Suppression of Crosstalk Stray Light in a Microlens Array Scanning and Searching System

The microlens array (MLA) system can aid in realizing fast beam deflection owing to the lateral displacement between arrays. The MLA system has the advantages of miniaturization and good functionality. However, during system operation, crosstalk beams are generated between each microlens array unit, introducing additional stray light, thus affecting the imaging contrast of the system. Therefore, this study uses the matrix operation method to trace the paraxial ray to trace the optical system and analyzes the generation mechanism of crosstalk stray light in the MLA system. Furthermore, this study proposes a crosstalk suppression method based on a stop array to reasonably suppress stray light. Finally, an example of an infrared array scanning infrared optical system is considered so as to verify the correctness and feasibility of the proposed crosstalk stray light suppression method. Therefore, this paper introduces the stray light suppression principle to guide the optical design process of the system, providing a theoretical basis for the design and analysis of the microlens array scanning and search system.

Tunable and Dynamic Optofluidic Microlens Arrays Based on Droplets

Microlens arrays (MLAs) are acquiring a key role in the micro-optical system, which have been widely applied in the fields of imaging processing, light extraction, biochemical sensing, and display technology. Compared with solid MLAs, liquid MLAs have received extensive attention due to their natural smooth interface and adjustability. However, manufacturing tunable liquid MLAs with ideal structures is still a key challenge for current technologies. In this paper, a novel and simple optofluidic method is demonstrated, enabling the tunable focusing and high-quality imaging of liquid MLAs. Tunable droplets are fabricated and self-assembled into arrays as the MLAs, which can be easily adjusted to focus, form images, and display different focal lengths. Tuning of MLAs' focusing properties (range from 550 to 5370 μm) is demonstrated by changing the refractive index (RI) of the droplets with a fixed size of 200 μm, which can be changed by adjusting the flow rates of the two branch streams. Also, the corresponding numerical apertures of the MLAs range from 0.026 to 0.26. Furthermore, the MLAs' functionality for microparticle imaging applications is also illustrated. Combining the MLAs with a 4× objective, microparticle imaging is magnified two times, and the resolution has also been improved on the original basis. Besides, both the size and RI of the MLAs in an optofluidic chip can be further adjusted to detect samples at different positions. These MLAs have the merits of high optical performance, a simple fabrication procedure, easy integration, and good tunability. Thus, it shows promising opportunities for many applications, such as adaptive imaging and sensing.

Artificial Hyper Compound Eyes Enable Variable-Focus Imaging on both Curved and Flat Surfaces

The artificial compound eye (ACE) with zoom imaging requires complex power sources. Meanwhile, its curved substrate makes it difficult for the ACE to realize the zoom imaging on flat surfaces. To realize a wide field of view and a zoom function on both curved and flat surfaces simultaneously, a novel ACE is proposed, which is a bionic design inspired by an ancient creature, trilobite. Compared with a dragonfly, photosensitive units of a trilobite's compound eye are composed of ommatidia with different focal lengths. By learning from this concept, an artificial hyper compound eye (AHCE) was fabricated. Its basic components are five microlenses with different curvatures, and they are capable of being treated as five ommatidia with different focal lengths. Five ommatidia form a photosensitive unit to realize a zoom function. AHCE is capable of variable-focus imaging on curved surfaces. With the information share function, we found that the AHCE not only images on curved surfaces but also has a zoom-imaging function on flat surfaces. The results confirm that the AHCE demonstrates an advanced imaging capability, a variable-focus imaging function on both curved and flat surfaces, which may open new opportunities in developing advanced micro-optical devices.

Microfluidic Fabrication of a PDMS Microlens for Imaging Tunability

A microfluidic system was created to fabricate polydimethylsiloxane (PDMS) microspheres, whose shape, surface smoothness, and size were controlled. Resulting from their excellent optical properties and elasticity prepared by the apparatus, each PDMS microsphere could act as a microlens and separate imaging unit. The focal length of the microlens was simply tuned by the forces posed on the beads. For the microlens array (MLA) application, it was constructed simply through the assembly of the monodisperse PDMS beads.

Tunable optofluidic microbubble lens

Optofluidic microlenses are one of the crucial components in many miniature lab-on-chip systems. However, many optofluidic microlenses are fabricated through complex micromachining and tuned by high-precision actuators. We propose a kind of tunable optofluidic microbubble lens that is made by the fuse-and-blow method with a fiber fusion splicer. The optical focusing properties of the microlens can be tuned by changing the refractive index of the liquid inside. The focal spot size is 2.8 µm and the focal length is 13.7 µm, which are better than those of other tunable optofluidic microlenses. The imaging capability of the optofluidic microbubble lens is demonstrated under a resolution test target and the imaging resolution can reach 1 µm. The results indicate that the optofluidic microbubble lens possesses good focusing properties and imaging capability for many applications, such as cell counting, optical trapping, spatial light coupling, beam shaping and imaging.