Optimal condition for employing an axicon-generated Bessel beam to fabricate cylindrical microlens arrays

Abstract

A numerical algorithm, modelling the transformation from a Gaussian beam to a Bessel beam, is presented for the purpose to study the optimal condition for employing an axicon-generated Bessel beam to fabricate cylindrical microlens arrays (CMLAs). By applying the numerical algorithm to simulate the spatial intensity distribution behind the axicon under different defects of a rotund-apex and different diameter ratios of an incident beam to the axicon, we find that the diffraction effects formed by the axicon edge can be almost eliminated when the diameter ratio is less than 1:2, but the spatial intensity distribution is disturbed dramatically even a few tens of microns deviation of the apex, especially for the front part of the axicon-generated Bessel beam. Fortunately, the lateral intensity profile in the rear part still maintains a desirable Bessel curve. Therefore, the rear part of the Bessel area and the less than 1:2 diameter ratio are the optimal choice for employing an axicon-generated Bessel beam to implement surface microstructures fabrication. Furthermore, by applying the optimal conditions to direct writing microstructures on fused silica with a femtosecond (fs) laser, a large area close-packed CMLA is fabricated. The CMLA presents high quality and uniformity and its optical performance is also demonstrated.