Method for fabricating microlenses

A method of fabricating in a photoresist material a replica of a designed microlens of any designed configuration, using a single exposure mask, and reproducing the replica directly in a substrate material, said method comprising,

• constructing a single exposure mask with a plurality of precisely located and sized light transmitting openings formed with sufficiently small specific opening sizes and located at a sufficiently large number of specific locations, correlated to related locations on the configuration of the designed microlens, to enable a replica image of the designed microlens to be produced in a photoresist material.
• exposing a related photoresist material to light of a selected wavelength and transmitted through said openings in said single mask for a selected duration of time,
• processing the exposed photoresist material to produce a replica in the photoresist material of the designed microlens, which replica can be used subsequently for producing the designed microlens in a substrate material,
• placing the photoresist material replica on a substrate material, and
• processing the replica and the substrate material to reproduce the replica directly in the substrate material.