Spin-mounted fabrication of injection molded micro-optics

Abstract

Methods and systems for fabrication of injection molded optical components are disclosed. In one embodiment, a moldplate having one or more cavities is configured to receive injected optical material within walls of the cavities. The cavities are designed with a predetermined geometric profile approximately corresponding to a predetermined optical profile of an optical element to be formed therein. When molten optical material is injected into the cavities of the moldplate, the injected optical material forms a meniscus due to surface tension between the optical material and the wall of the cavities. The meniscus thus provides a shape corresponding to the predetermined optical profile. The optical material is then rapidly cured with actinic radiation, and a desired optical element with high-precision dimensions is formed within the cavities of the moldplate. In some embodiments, the moldplate is spun around a spin axis such that the meniscus is adjusted to match the predetermined optical profile within a certain tolerance.

Dependencies are inferred from the claim text.