Fabrication of polymer microlens array with controllable focal length by modifying surface wettability

A straightforward technique for fabricating low-cost microlens arrays with controllable focal length is developed. By harnessing and manipulating the interfacial energy between the liquid-state acrylate resin and the solidified polydimethylsiloxane (PDMS), the surface of the acrylate resin in the PDMS microhole presents a spherical shape and the curvature can be flexibly controlled. With the change of the processing time for the surface modification of the PDMS microholes, the focal length of the concave microlenses varies from -296.3 μm to -67.4 μm. The numerical aperture of 0.45 is realized. The focal length and the aperture of the microlenses are also affected by the diameter of the microholes. The fabricated concave microlens array can be employed as a master to further duplicate convex microlens array. A good image quality can be achieved by using the convex microlens arrays.