We machine lens arrays using our patented Dynamic Part Indexing technology. This unique system brings the best ultra-precision machining technique, i.e. on-axis turning, to arrays of all kinds. If one single optical surface of your array can be made using on-axis turning, then we can make it into an array ! For more information regarding DPI, take a look at our Technology page.

Micro lens arrayMicro lens array

Sequential on-axis turning brings many advantages compared to the classical freeform machining techniques (slow-slide servo, fast-tool servo and diamond micro-milling). Amongst others: lower surface form error (and more rotationally symmetrical), lower machining times, more geometrical freedom, true 100% fill factor (with extremely sharp edges between intersecting lenses), lower surface roughness figures, etc.

Applications Injection molding, roll-to-roll hot embossing, polymer-on-glass wafer-level optics
Process Sequential on-axis diamond-turning of each optical surface (relocation of the monolithic workpiece)
Size, number of lenses/elements Max 200 mm diameter, hundreds to thousands
Designs Spherical, highly aspherical, freeform, Fresnel, diffractive
Fill factor Up to 100%
Lens-to-lens pitch accuracy 1-2 µm
Form accuracy PV 100 nm, repeatable on each element
Surface finish Typically 2 nm Ra
Slopes Up to 90°
Materials NiP, Al, RSA, Cu, CuZn, etc

Possible applications are numerous and cover a wide range of industries. We have already successfully applied this technology to:

  • Lens arrays for LED illumination in automotive
  • Masters for eletro-forming in roll-to-roll hot embossing
  • Monolithic multi-cavity molds for imaging in mobile phones
  • Injection mold inserts for LED illumination
  • Lens arrays for augmented reality and virtual reality
  • etc.

Parabolic lens insertParabolic lens insertMobile phone camera lens insertCD format lens insert