Fabrication of diffractive optical elements by programmable thermocapillary shaping of thin liquid films (original) (raw)
Diffractive optical elements (DOEs) enable precise manipulation of wavefronts and are widely used in a variety of optical systems. However, their fabrication relies on lithography or high precision machining processes that are long, expensive, and infrastructure-heavy. We here present a one-step rapid fabrication method that leverages the thermocapillary effect to shape thin liquid films into useful DOEs with sub-nanometeric surface roughness. Our system consists of a projection system, which illuminates any desired pattern onto the bottom of a fluidic chamber patterned with heat-absorbing pads. The heat induces surface tension gradients in the polymer-air interface, resulting in the polymer film deformation. The polymer is then photocured to yield a solid device. We developed a theoretical model that provides the required projection pattern to achieve a desired topography. Based on this model, we demonstrate the fabrication of several DOEs, including phase masks for extended depth ...
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