Thermocompression molding of plastic optical elements

A method of forming a plastic lens element, comprising:

• positioning a deformable carrier tape on a first die mold including a plurality of lens shaped cavities;
• dispensing a quantity of a liquid precursor material onto the carrier tape;
• bringing a second die mold into contact with the carrier tape and the first die mold;
• applying pressure to the first die mold and the second die mold and pumping air out of a mold chamber between the first die mold and the second die mold so that the deformable carrier tape is pressed into the plurality of lens shaped cavities between the first die mold and the liquid precursor material to form a sheet of plastic lenses connected at peripheral regions of the lenses;
• opening the first die mold and the second die mold;
• removing the sheet of plastic lenses from the first die mold;
• advancing the deformable carrier tape to move the sheet of plastic lenses away from the first die mold and the second die mold and to move the deformable carrier tape including the sheet of plastic lenses into a heater;
• curing the sheet of plastic lenses in the heater while the sheet of plastic lenses is on the deformable carrier tape;
• and
• separating at least one plastic lens from the sheet of plastic lenses.