Low-cost, high-volume, manufacturable 0.88 NA multi-wavelength diffractive lens array for optical document security

We design, manufacture, and characterize a high-numerical-aperture (NA=0.88, f/0.27), multi-wavelength (480 nm, 550 nm, and 650 nm) multilevel diffractive microlens array (MLA). This MLA achieves multi-wavelength focusing with a depth of focus (DoF) twice the diffraction-limited value. Each microlens in the array is closely packed with a diameter of 70 µm and a focal length of 19 µm in air. The MLA is patterned on one surface of a polymer film via UV casting, positioning the focal plane at the distal end of the polymer film. Each microlens focuses light at three design wavelengths into a focal spot with an estimated FWHM of ∼310nm. By placing this MLA directly on a standard high-resolution banknote print (minimum feature width of 10–15 µm), we demonstrate color-integral imaging for anti-counterfeiting. In contrast, refractive MLAs cannot achieve high-NA, multi-wavelength focusing or extended DoF. The extended DoF of our MLA ensures reliable performance despite variations in the polymer film’s thickness. Our MLA, produced via UV casting, enables extremely low-cost, high-volume production, making it ideal for flat optics in banknotes and document security.