Microforging technique for fabrication of spherical lens array mold

This paper addressed a fabricating method for spherical lens array mold by microforging. The silicon nitride ceramic balls were performed as indenter on metal materials, such as aluminum alloy, to generate dimples with spherical cross-sectional profiles. Under the proper processing conditions, the spherical lens array mold was fabricated. The effects of indentation force, depth, and pressing time were experimentally investigated. In addition, the morphology and surface property of microforged mold were inspected. Subsequently, the thermoplastic polymer spherical lens array was formed through hot embossing process. The optical performance, such as light spots and focal lengths, was detected. This technique shows great potential for mass production of spherical lens array mold.