3D Printed Microlenses for Microprojector Manufacturing
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Solution Overview
Problem
Current methods for manufacturing microprojectors are limited in their ability to efficiently produce customized microlenses with precise optical parameters, leading to variations in image quality and complexity in projection systems.
Innovation Solution
The method involves using 3D printing with hybrid polymer ink to create customized microlenses, where the number of droplets and wetting properties are controlled to achieve desired optical parameters, allowing for individualized microlens production with precise focal lengths and shapes, enabling improved image formation and projection capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for microlenses, then production process is standardized, but manufacturing precision and customization capability deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the number of droplets, their size, and wetting properties during the printing process to achieve desired optical parameters (focal length, curvature) for customized microlenses. This allows precise control of lens characteristics while maintaining a relatively simple printing-based manufacturing process.
Solution Approach 2:
The patent implements local quality by enabling individual customization of each microlens through controlled droplet deposition. Each lens can have different optical parameters (focal length, curvature radius) tailored to specific requirements, while the overall manufacturing process remains standardized and efficient.
2Manufacturing precision
If conventional manufacturing methods are used for microlenses, then production process is simple, but manufacturing precision and image quality deteriorate
Solution Approach 1:
By controlling droplet parameters (number, size, spacing) and wetting properties, the patent achieves precise focal length control for each microlens. This precision is achieved through a relatively simple printing process rather than complex multi-step manufacturing, thereby improving manufacturing precision without proportionally increasing device complexity.
Solution Approach 2:
The patent replaces traditional mechanical microlens fabrication methods (such as precision molding or grinding) with a printing-based approach. This substitution enables precise control of optical parameters through digital control of droplet deposition, simplifying the manufacturing system while improving precision.
3Manufacturing precision
If customized microlenses are produced with precise optical parameters, then image quality improves, but production efficiency deteriorates
Solution Approach 1:
The printing-based manufacturing method serves multiple functions: it can produce both standardized and customized microlenses using the same equipment and process. By controlling droplet parameters, the system can efficiently produce lenses with precise optical parameters without requiring separate production lines, thereby maintaining high productivity while achieving customization.
Solution Approach 2:
The patent achieves precise optical parameters through controlled parameter changes in the printing process (droplet number, size, spacing, wetting control). This allows customized lenses to be produced with high precision directly during manufacturing rather than requiring post-processing or selection, maintaining production efficiency while achieving the desired precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in microprojectors with enhanced image quality and reduced system complexity, enabling efficient production of microprojectors with customized optical parameters and improved projection performance.
Implementation Method 1
printing is effected with a hybrid polymer 'ink'... several droplets are printed onto one point to build up a drop (microlens after its curation)
Data Source
AI summary
The invention relates to a method of manufacturing a microprojector for a projection display, wherein the microprojector comprises a support on which a projector lens array with a plurality of projector lenses is arranged, wherein on a side of the support facing away from the projector lens array, an object structure array with a plurality of e.g. identical object structures is arranged, wherein at least one projector lens is associated with one object structure such that the projections of the object structures superpose through the projector lenses to form a full image, wherein e.g. the distance between a projector lens and the associated object structures corresponds to the focal length of the respective projector lens, wherein on the object structure array, a condenser lens array is arranged such that in case of an illumination of the condenser lens array, a Köhler illumination of the object structures or projector lens associated with the respective condenser lenses is permitted.