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Numerical and experimental study on multiphase printing of polymeric biconvex micro lenses

Polymeric micro lenses have been popularly used in optical systems in recent decades due to the advantages of being lightweight and low-cost compared to traditional glass lenses. The multiphase printing method is a novel polymeric micro lens manufacturing method. It has the advantage of low-cost and high accuracy. To precisely control the fabrication parameters, it is important to study the influence of forming conditions on lens shape. This work developed and validated a numerical model that utilizes the Young–Laplace equation, Navier–Stokes equation, forces balance, and mass conservation to calculate the profile of the printed polymeric micro lens and to study the effects of different manufacturing parameters. Experimental validation showed that the numerical model can achieve accurate lens geometry by knowing the printing conditions. This numerical method will significantly simplify the manufacturing process of polymeric lenses, and shows the promising potential for the multiphase printing method.