The lens shape plays a major role in the design of a custom MLA. However, the mechanical and material properties are also critical. A large range of high quality polymers and substrate materials can be used to produce MLAs, each requiring well defined replication processes in order to meet the most demanding specifications.

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For many of the reasons detailed above, many customers that require high volume components have designed their products to make use of the extensive worldwide wafer-level infrastructure that exists.  This is accomplished by designing a master that includes hundreds or thousands of individual dies, that once replicated, can be singulated (typically diced) into their individual component size.  Common standard wafer sizes include 100mm, 150mm and 200mm diameters, but the replication process also allows for custom sized plates or wafers that can be larger than 500mm round or square.  Wafer-level manufacturing is an exceptionally cost effective way to reduce the recurring costs of these components to levels that are similar to injected molded optics.  After the MLA array is replicated onto the glass wafer, the wafer is typically shipped to system integrators, where the MLA wafer is paired with several other wafers, or stacks of wafers to create complex sensor or emitter systems.

For instance, the imaging lens, camera sensor, image capture boards, and video cables each have their associated MTF. By analyzing the system MTF curve, designers can determine which combination of components will provide sufficient performance for a given application, considering factors like contrast requirements and resolution.

MTF, as its name suggests, measures a lens’s capability to transfer contrast at specific resolutions from the object to the image. It combines both resolution and contrast into a single specification. As the line spacing decreases (frequency increases) on the test target, it becomes progressively challenging for the lens to efficiently transfer this decrease in contrast, resulting in a decrease in MTF.

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Below are the fundamental building blocks and design rules that are required for the optical designer to develop a complete specification for a custom MLA:

MTF is a powerful tool to quantify the overall imaging performance of a system in terms of resolution and contrast. Understanding the MTF curves of each imaging lens and camera sensor within a system allows designers to make informed choices when optimizing for specific resolutions.

An MLA is specified as either a transmissive or a reflective element.  As a replicated optic, the polymer used will generally define the transmission range which typically is in the range of ~400nm to ~2700nm.  Anti-reflection (AR) coatings can be applied to these components to further enhance their transmission efficiency.  The AR coating can be tailored to meet each application’s specific needs. If an AR coating is required, the designer must specify the AR coating’s maximum reflectivity over the operating wavelength range.  If the component is specified as a reflective element, a reflective coating is applied to the MLA to create a micromirror array.  Much like the AR coatings, the reflective coatings can be tailored to meet each application’s operating wavelength range and reflective coating performance requirements.

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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. MLAs can be found in numerous products across a range of industries (See Markets Page). Below are the fundamental building blocks and design rules that are required for the optical designer to develop a complete specification for a custom MLA:

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In conclusion, the Modulation Transfer Function is a pivotal parameter for evaluating and optimizing optical systems. By understanding resolution, contrast, and how MTF combines these factors, optical designers can make informed decisions to select the right components and achieve superior image quality for their applications. MTF data serves as a powerful tool in the hands of those seeking precision and excellence in optical system design.

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The illustration below provides a graphic presentation of the number of replicated wafers that can be produced using our multi-generation stamper tool approach. In this example, 81 Gen4 final replicas can be produced from a single Gen0 master, with each tool producing 3 daughter tools/replicas as shown (3^4 = 81). Depending on the micro-structure details and performance specifications required, it is possible to produce hundreds of tools/replicas from each tool which rapidly increases the number of Gen4 final replicas that can be produced (100^4 = 100 Million!).

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MLAs can be found in numerous products across a range of industries (See Markets Page). Below are the fundamental building blocks and design rules that are required for the optical designer to develop a complete specification for a custom MLA:

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The shape of the lens is one of the most critical parameters of the MLA.  There are very few limitations to consider when deciding on the microlens array shape and profile.  For tightly toleranced lens profiles, greyscale laser lithography is used to produce the master.  Greyscale laser lithography allows the flexibility necessary to produce a variety of lens types, sizes and packing configurations.  The following information is required in order to manufacture a custom MLA:

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The Modulation Transfer Function (MTF) is a vital parameter used to assess the performance of optical systems, ranging from simple lenses to complex imaging lens assemblies. It serves as a standardized quantitative measure for optical designers and microscopists to evaluate and compare lenses for various applications such as DNA sequencers, cell analyzers, slide scanners, and industrial inspection equipment. In this article, we will delve into the details of MTF, exploring its components, significance, and applications.

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Microlens arrays cannot be tested via traditional lens testing methods.  In order to evaluate the lenslet profiles, more sophisticated measurement equipment is required.

In traditional system integration, the resolution is often estimated based on the principle of the weakest link, assuming that the system’s resolution is solely limited by the component with the lowest resolution. However, this approach is flawed as every component within the system contributes to image quality, and the overall MTF of the system is the product of all the MTF curves of its components.

In most cases, in order to produce the MLA, custom tooling (including masters and stampers) must be produced, and new or modified production processes are required.

Resolution and contrast are fundamental factors in achieving sharp and clear images. Resolution pertains to an imaging system’s ability to distinguish fine object details and is typically expressed in line-pairs per millimeter (lp/mm), where each line-pair consists of a black line followed by a white line. Contrast, on the other hand, measures an optical system’s ability to distinguish between light and dark areas in an image.

High-quality optics excel in transferring contrast at higher spatial frequencies, which translates to higher resolution. To assess this ability, MTF comes into play. MTF quantifies a lens’s capacity to transfer the contrast of a sample to an image using spatial frequency (resolution). Spatial frequency is defined as the number of line pairs per millimeter (lp/mm). Typically, MTF is determined using test charts featuring alternating black and white lines.