Direct Laser Printing of Tailored Polymeric Microlenses

Liquid crystal doped photopolymer micro-droplets printed by a simple and clean laser-induced forward transfer process

We print a tunable photopolymer (photopolymer dispersed liquid crystal -PDLC), using the laser-induced direct transfer technique without absorber layer, which was a challenge for this technique given the low absorption and high viscosity of PDLC, and which had not been achieved so far to our knowledge. This makes the LIFT printing process faster and cleaner and achieves a high-quality printed droplet (aspheric profile and low roughness). A femtosecond laser was needed to reach sufficiently peak energies to induce nonlinear absorption and eject the polymer onto a substrate. Only a narrow energy window allows the material to be ejected without spattering.

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.

Printing via Laser-Induced Forward Transfer and the Future of Digital Manufacturing

In the last decades, digital manufacturing has constituted the headline of what is starting to be known as the 'fourth industrial revolution', where the fabrication processes comprise a hybrid of technologies that blur the lines between fundamental sciences, engineering, and even medicine as never seen before. One of the reasons why this mixture is inevitable has to do with the fact that we live in an era that incorporates technology in every single aspect of our daily lives. In the industry, this has translated into fabrication versatility, as follows: design changes on a final product are just one click away, fabrication chains have evolved towards continuous roll-to roll processes, and, most importantly, the overall costs and fabrication speeds are matching and overcoming most of the traditional fabrication methods. Laser-induced forward transfer (LIFT) stands out as a versatile set of fabrication techniques, being the closest approach to an all-in-one additive manufacturing method compatible with virtually any material. In this technique, laser radiation is used to propel the material of interest and deposit it at user-defined locations with high spatial resolution. By selecting the proper laser parameters and considering the interaction of the laser light with the material, it is possible to transfer this technique from robust inorganic materials to fragile biological samples. In this work, we first present a brief introduction on the current developments of the LIFT technique by surveying recent scientific review publications. Then, we provide a general research overview by making an account of the publication and citation numbers of scientific papers on the LIFT technique considering the last three decades. At the same time, we highlight the geographical distribution and main research institutions that contribute to this scientific output. Finally, we present the patent status and commercial forecasts to outline future trends for LIFT in different scientific fields.

Polarization-Sensitive Patterning of Azopolymer Thin Films Using Multiple Structured Laser Beams

The polarization sensitivity of azopolymers is well known. Therefore, these materials are actively used in many applications of photonics. Recently, the unique possibilities of processing such materials using a structured laser beam were demonstrated, which revealed the key role of the distribution of polarization and the longitudinal component of light in determining the shape of the nano- and microstructures formed on the surfaces of thin azopolymer films. Here, we present numerical and experimental results demonstrating the high polarization sensitivity of thin azopolymer films to the local polarization state of an illuminating structured laser beam consisting of a set of light spots. To form such arrays of spots with a controlled distribution of polarization, different polarization states of laser beams, both homogeneous and locally inhomogeneous, were used. The results obtained show the possibility of implementing a parallel non-uniform patterning of thin azopolymer films depending on the polarization distribution of the illuminating laser beam. We believe that the demonstrated results will not only make it possible to implement the simultaneous detection of local polarization states of complex-shaped light fields but will also be used for the high-performance fabrication of diffractive optical elements and metasurfaces.

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.

Biomimetic apposition compound eye fabricated using microfluidic-assisted 3D printing

After half a billion years of evolution, arthropods have developed sophisticated compound eyes with extraordinary visual capabilities that have inspired the development of artificial compound eyes. However, the limited 2D nature of most traditional fabrication techniques makes it challenging to directly replicate these natural systems. Here, we present a biomimetic apposition compound eye fabricated using a microfluidic-assisted 3D-printing technique. Each microlens is connected to the bottom planar surface of the eye via intracorporal, zero-crosstalk refractive-index-matched waveguides to mimic the rhabdoms of a natural eye. Full-colour wide-angle panoramic views and position tracking of a point source are realized by placing the fabricated eye directly on top of a commercial imaging sensor. As a biomimetic analogue to naturally occurring compound eyes, the eye's full-colour 3D to 2D mapping capability has the potential to enable a wide variety of applications from improving endoscopic imaging to enhancing machine vision for facilitating human-robot interactions.

High-resolution imaging and fast number estimation of suspended particles using dewetted polymer microlenses in a microfluidic channel

We have fabricated polymer micro-lens array by self-organized dewetting inside the microchannel, which shows remarkable enhancement in the resolution, contrast and more than 10 times add-on magnification to a microscope. These lenses are demonstrated to resolve sub-micrometer features and detect moving micro-particles when suspension is flown in a microchannel. Polystyrene (PS) micro-lenses are fabricated on a polydimethylsiloxane (PDMS) substrate using the controlled dewetting of PS thin film then this PDMS substrate is used to close the microchannel with inverted micro-lenses on it. An aqueous suspension of polystyrene particles is flown through the microchannel and we have observed the particles through an optical microscope. Focusing and magnification through PS micro-lenses is analyzed to get a quantitative estimate of the particle number density in the solution. This method offers a promising low-cost high throughput solution for determining the approximate number density of flowing particles or suitably stained biological cells. Particularly in a pathology lab it can tremendously increase detection limit by enabling visibility of sub-micrometer pathogens using a standard laboratory microscope.

Fabrication of Multifocal Microlens Array by One Step Exposure Process

Microlenses can be widely used in integrated micro-optical systems. However, in some special applications, such as light field imaging systems, multifocal microlens arrays (MLA) are expected to improve imaging resolution. For the fabrication of multifocal MLA, the traditional fabrication method is no longer applicable. To solve this problem, a fabrication method of multifocal MLA by a one step exposure process is proposed. Through the analyses and research of photoresist AZ9260, the nonlinear relationship between exposure dose and exposure depth is established. In the design of the mask, the mask pattern is corrected according to the nonlinear relationship to obtain the final mask. The continuous surface of the multifocal MLA is fabricated by the mask moving exposure. The experimental results show that the prepared multifocal MLA has high filling factor and surface fidelity. What is more, this method is simple and efficient to use in practical applications.

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

Tunable microlens arrays (MLAs) with controllable focal lengths have been extensively used in optical sensors, biochips, and electronic devices. The commonly used method is electrowetting on dielectric (EWOD) that controls the contact angle of the microlens to adjust the focal length. However, the fabrication of tunable MLAs at the microscale remains a challenge because the size of MLAs is limited by the external electrodes of EWOD. In this study, a highly integrated planar annular microelectrode array was proposed to achieve an electrowetting tunable MLA. The planar microelectrode was fabricated by electrohydrodynamic jet (E-jet) printing and the liquid microlens was then deposited in situ on the microelectrode. This method could realize 36 tunable liquid microlenses with an average diameter of 24 μm in a 320 × 320 μm² plane. The fabricated tunable MLAs with higher integration levels and smaller sizes can be beneficial for cell imaging, optofluidic systems, and microfluidic chips.

3D Printing of a PDMS Cylindrical Microlens Array with 100% Fill-Factor

Cylindrical microlens arrays (CMLAs) play a key role in many optoelectronic devices, and 100% fill-factor CMLAs also have the advantage of improving the signal-to-noise ratio and avoiding stray-light effects. However, the existing preparation technologies are complicated and costly, which are not suitable for mass production. Herein, we propose a simple, efficient, and low-cost manufacturing method for CMLAs with a high fill-factor via the electric-field-driven (EFD) microscale 3D printing of polydimethylsiloxane (PDMS). By adjusting the printing parameters, the profile and the fill-factor of the CMLAs can be controlled to improve their optical performance. The optical performance test results show that the printed PDMS CMLAs have good image-projecting and light-diffraction properties. Using the two printing modes of this EFD microscale 3D-printing technology, a cylindrical dual-microlens array with a double-focusing function is simply prepared. At the same time, we print a series of specially shaped microlenses, proving the flexible manufacturing capabilities of this technology. The results show that the prepared CMLAs have good morphology and optical properties. The proposed method may provide a viable route for manufacturing large-area CMLAs with 100% fill-factor in a very simple, efficient, and low-cost manner.

Microlenses arrays: Fabrication, materials, and applications

Microlenses have become an indispensable optical element in many optical systems. The advancement of technology has led to a wider variety of microlenses fabrication methods, but these methods suffer from, more or less, some limitations. In this article, we review the manufacturing technology of microlenses from the direct and indirect perspectives. First, we present several fabrication methods and their advantages and disadvantages are discussed. Then, we discuss the commonly used materials for fabricating microlenses and the applications of microlenses in various fields. Finally, we point out the prospects for the future development of microlenses and their fabrication methods.

Fabrication of Waterproof Artificial Compound Eyes with Variable Field of View Based on the Bioinspiration from Natural Hierarchical Micro-Nanostructures

Planar and curved microlens arrays (MLAs) are the key components of miniaturized microoptical systems. In order to meet the requirements for advanced and multipurpose applications in microoptical field, a simple manufacturing method is urgently required for fabricating MLAs with unique properties, such as waterproofness and variable field-of-view (FOV) imaging. Such properties are beneficial for the production of advanced artificial compound eyes for the significant applications in complex microcavity environments with high humidity, for instance, miniature medical endoscopy. However, the simple and effective fabrication of advanced artificial compound eyes still presents significant challenges. In this paper, bioinspired by the natural superhydrophobic surface of lotus leaf, we propose a novel method for the fabrication of waterproof artificial compound eyes. Electrohydrodynamic jet printing was used to fabricate hierarchical MLAs and nanolens arrays (NLAs) on polydimethylsiloxane film. The flexible film of MLAs hybridized with NLAs exhibited excellent superhydrophobic property with a water contact angle of 158°. The MLAs film was deformed using a microfluidics chip to create artificial compound eyes with variable FOV, which ranged from 0° to 160°.

Cross-scale additive direct-writing fabrication of micro/nano lens arrays by electrohydrodynamic jet printing

High-quality micro/nanolens arrays (M/NLAs) are becoming irreplaceable components of various compact and miniaturized optical systems and functional devices. There is urgent requirement for a low-cost, high-efficiency, and high-precision technique to manufacture high-quality M/NLAs to meet their diverse and personalized applications. In this paper, we report the one-step maskless fabrication of M/NLAs via electrohydrodynamic jet (E-jet) printing. In order to get the best morphological parameters of M/NLAs, we adopted the stable cone-jet printing mode with optimized parameters instead of the micro dripping mode. The optical parameters of M/NLAs were analyzed and optimized, and they were influenced by the E-jet printing parameters, the wettability of the substrate, and the viscosity of the UV-curable adhesive. Thus, diverse and customized M/NLAs were obtained. Herein, we realized the fabrication of nanolens with a minimum diameter of 120 nm, and NLAs with different parameters were printed on a silicon substrate, a cantilever of atomic force microscopy probe, and single-layer graphene.

Moldless Printing of Silicone Lenses With Embedded Nanostructured Optical Filters

Optical lenses are among the oldest technological innovations (3000 years ago) and they have enabled a multitude of applications in healthcare and in our daily lives. The primary function of optical lenses has changed little over time; they serve mainly as a light-collection (e.g. reflected, transmitted, diffracted) element, and the wavelength and/or intensity of the collected light is usually manipulated by coupling with various external optical filter elements or coatings. This generally results in losses associated with multiple interfacial reflections, and increases the complexity of design and construction. In this work we introduce a change in this paradigm, by integrating both light-shaping and image magnification into a single lens element using a moldless procedure that takes advantage of the physical and optical properties of mesoporous silicon (PSi) photonic crystal nanostructures. Casting of a liquid poly(dimethyl) siloxane (PDMS) pre-polymer solution onto a PSi film generates a droplet with contact angle that is readily controlled by the silicon nanostructure, and adhesion of the cured polymer to the PSi photonic crystal allows preparation of lightweight (10 mg) freestanding lenses (4.7 mm focal length) with an embedded optical component (e.g. optical rugate filter, resonant cavity, distributed Bragg reflector). Our fabrication process shows excellent reliability (yield 95%) and low cost and we expect our lens to have implications in a wide range of applications. As a proof-of-concept, using a single monolithic lens/filter element we demonstrate: fluorescence imaging of isolated human cancer cells with rejection of the blue excitation light, through a lens that is self-adhered to a commercial smartphone; shaping the emission spectrum of a white light emitting diode (LED) to tune the color from red through blue; and selection of a narrow wavelength band (bandwidth 5 nm) from a fluorescent molecular probe.

New Strategy to Achieve Laser Direct Writing of Polymers: Fabrication of the Color-Changing Microcapsule with a Core-Shell Structure

This paper proposed an efficient and environmentally friendly strategy to prepare a new color-changing microcapsule with a core-shell structure for laser direct writing of polymers, and only the physical melt blending of polymers was employed. The laser absorber (SnO₂) and the easily carbonized polymer (PC) were designed as the "core" and the "shell" of the microcapsule, respectively. The microcapsules were in situ formed during melt blending. Scanning electron microscopy, transmission electron microscopy, and energy-dispersive spectrometry confirmed the successful preparation of SnO₂/PC microcapsules with a core-shell structure. Their average diameter was 2.2 μm, and the "shell" thickness was 0.21-0.24 μm. As expected, these SnO₂/PC microcapsules endowed polymers with an outstanding performance of near-infrared (NIR) laser direct writing. Raman spectroscopy and X-ray photoelectron spectroscopy indicated that the color change was ascribed to the polymer carbonization because of the instantaneous high temperature caused by the SnO₂ absorption of NIR laser energy. Optical microscopy observed a thick carbonization layer of 234 μm. Moreover, Raman depth imaging revealed the carbonization distribution, confirming that the amorphous carbon produced by the carbonization of the PC "shell" is the key factor of SnO₂/PC microcapsules to provide polymers an outstanding performance of laser direct writing. This color-changing microcapsule has no selectivity to polymers because of providing a black color source (the carbonization of PC) itself, ensuring the high contrast and precision of patterns or texts after laser direct writing for all general-purpose polymers. We believe that this novel strategy to achieve laser direct writing of polymers will have broad application prospects.

Ultrafast Three-Dimensional Printing of Optically Smooth Microlens Arrays by Oscillation-Assisted Digital Light Processing

A microlens array has become an important micro-optics device in various applications. Compared with traditional manufacturing approaches, digital light processing (DLP)-based printing enables fabrication of complex three-dimensional (3D) geometries and is a possible manufacturing approach for microlens arrays. However, the nature of 3D printing objects by stacking successive 2D patterns formed by discrete pixels leads to coarse surface roughness and makes DLP-based printing unsuccessful in fabricating optical components. Here, we report an oscillation-assisted DLP-based printing approach for fabrication of microlens arrays. An optically smooth surface (about 1 nm surface roughness) is achieved by mechanical oscillation that eliminates the jagged surface formed by discrete pixels, and a 1-3 s single grayscale ultraviolet (UV) exposure that removes the staircase effect. Moreover, computationally designed grayscale UV patterns allow us to fabricate microlenses with various profiles. The proposed approach paves a way to 3D print optical components with high quality, fast speed, and vast flexibility.

Micro-optical Components for Bioimaging on Tissues, Cells and Subcellular Structures

Bioimaging generally indicates imaging techniques that acquire biological information from living forms. Among different imaging techniques, optical microscopy plays a predominant role in observing tissues, cells and biomolecules. Along with the fast development of microtechnology, developing miniaturized and integrated optical imaging systems has become essential to provide new imaging solutions for point-of-care applications. In this review, we will introduce the basic micro-optical components and their fabrication technologies first, and further emphasize the development of integrated optical systems for in vitro and in vivo bioimaging, respectively. We will conclude by giving our perspectives on micro-optical components for bioimaging applications in the near future.

Spraying dynamics in continuous wave laser printing of conductive inks

Laser-induced forward transfer (LIFT), though usually associated with pulsed lasers, has been recently shown to be feasible for printing liquid inks with continuous wave (CW) lasers. This is remarkable not only because of the advantages that the new approach presents in terms of cost, but also because of the surprising transfer dynamics associated with it. In this work we carry out a study of CW-LIFT aimed at understanding the new transfer dynamics and its correlation with the printing outcomes. The CW-LIFT of lines of Ag ink at different laser powers and scan speeds revealed a range of conditions that allowed printing conductive lines with good electrical properties. A fast-imaging study showed that liquid ejection corresponds to a spraying behavior completely different from the jetting characteristic of pulsed LIFT. We attribute the spray to pool-boiling in the donor film, in which bursting bubbles are responsible for liquid ejection in the form of projected droplets. The droplet motion is then modeled as the free fall of rigid spheres in a viscous medium, in good agreement with experimental observations. Finally, thermo-capillary flow in the donor film allows understanding the evolution of the morphology of the printed lines with laser power and scan speed.

Fabrication of polymer microlens array with controllable focal length by modifying surface wettability

A straightforward technique for fabricating low-cost microlens arrays with controllable focal length is developed. By harnessing and manipulating the interfacial energy between the liquid-state acrylate resin and the solidified polydimethylsiloxane (PDMS), the surface of the acrylate resin in the PDMS microhole presents a spherical shape and the curvature can be flexibly controlled. With the change of the processing time for the surface modification of the PDMS microholes, the focal length of the concave microlenses varies from -296.3 μm to -67.4 μm. The numerical aperture of 0.45 is realized. The focal length and the aperture of the microlenses are also affected by the diameter of the microholes. The fabricated concave microlens array can be employed as a master to further duplicate convex microlens array. A good image quality can be achieved by using the convex microlens arrays.

Generating liquid nanojets from copper by dual laser irradiation for ultra-high resolution printing

When the energy of a short laser pulse is localized in a fluid material, a flow motion is induced that can lead to the generation of free-surface jets. This nozzle-free jetting process is exploited to print conductive materials, typically metal nanoparticle inks, but this approach remains limited to the transfer of low viscosity fluids with a minimum feature size of few micrometers. We introduce a dual-laser method to achieve reproducible high-aspect-ratio jets from thin solid films. A first laser irradiation induces the melting of copper thin films and a second synchronized short pulse irradiation initiates the jetting process. Using time-resolved microscopy, we investigate the influence of the film thickness on the flow motion mechanisms and the ejection dynamics. For a wide range of laser fluences, we present observations similar to those obtained when the jets are generated by a single laser pulse from liquid donor films. The use of a solid film allows reducing the film thickness and then the volume of transferred material. Finally, we analyze these results in the perspective of using this double pulse LIFT technique for additive manufacturing of nano-micro-structures. Stable jets are formed from the copper films over distances exceeding 50-μm and are exploited to demonstrate periodic printing of 1.5-μm diameter droplets.

Fluid jet-array parallel machining of optical microstructure array surfaces

Optical microstructure array surfaces such as micro-lens array surface, micro-groove array surface etc., are being used in more and more optical products, depending on its ability to produce a unique or particular performance. The geometrical complexity of the optical microstructures array surfaces makes them difficult to be fabricated. In this paper, a novel method named fluid jet-array parallel machining (FJAPM) is proposed to provide a new way to generate the microstructure array surfaces with high productivity. In this process, an array of abrasive water jets is pumped out of a nozzle, and each fluid jet simultaneously impinges the target surface to implement material removal independently. The jet-array nozzle was optimally designed firstly to diminish the effect of jet interference based on the experimental investigation on the 2-Jet nozzles with different jet intervals. The material removal and surface generation models were built and validated through the comparison of simulation and experimental results of the generation of several kinds of microstructure array surfaces. Following that, the effect of some factors in the process was discussed, including the fluid pressure, nozzle geometry, tool path, and dwell time. The experimental results and analysis prove that FJAPM process is an effective way to fabricate the optical microstructure array surface together with high productivity.

Low-Cost Fabrication of Printed Electronics Devices through Continuous Wave Laser-Induced Forward Transfer

Laser-induced forward transfer (LIFT) is a direct-writing technique that allows printing inks from a liquid film in a similar way to inkjet printing but with fewer limitations concerning ink viscosity and loading particle size. In this work, we prove that liquid inks can be printed through LIFT by using continuous wave (CW) instead of pulsed lasers, which allows a substantial reduction in the cost of the printing system. Through the fabrication of a functional circuit on both rigid and flexible substrates (plastic and paper), we provide a proof-of-concept that demonstrates the versatility of the technique for printed electronics applications.