Precision micro-optical elements and the method of making precision micro-optical elements

Method of forming micro-optical elements comprising:

• providing a substrate having a surface with at least one structural opening defined by an edge extending below the surface of the substrate and leading into a support surface, wherein the support surface has an aperture through the substrate positioned centrally with respect to the edge, wherein both the structural opening and the support surface aperture are circular to form a circular structural opening and a circular aperture.
• providing a digitally-driven printhead containing an optical fluid the printhead having an orifice from which micro-droplets of said fluid are ejected in response to control signals;
• depositing a plurality of micro-droplets of said optical fluid into said circular structural opening;
• filling the circular structural opening with micro-droplets of said optical fluid deposited from said printhead until a micro-optical element is formed in the circular structural opening, such that a portion of the micro-optical element extends above the surface of the substrate and the portion extending above the surface of the substrate is formed by the edge;
• and
• hardening the micro-optical element.

Method of forming micro-optical elements comprising:

• providing a substrate having a surface with at least one structural opening defined by an edge extending below the surface of the substrate and leading into a support surface, wherein the support surface has an aperture through the substrate positioned centrally with respect to the edge, wherein both the structural opening and the aperture of the support surface are elongated to form an elongated structural opening and an elongated aperture.
• providing a digitally-driven printhead containing an optical fluid, the printhead having an orifice from which micro-droplets of said fluid are ejected in response to control signals;
• depositing a plurality of micro-droplets of said optical fluid into said structural opening;
• filling the elongated structural opening with micro-droplets of said optical fluid deposited from said printhead until a micro-optical element is formed in the elongated structural opening, such that a portion of the micro-optical element extends above the surface of the substrate and the portion extending above the surface of the substrate is formed by the edge;
• and
• hardening the micro-optical element.