3D printing of customized aspheric lenses for imaging

Abstract

A simple and efficient process for fabricating customized aspheric lenses is reported, in which a stereolithographic 3D printer combined with the meniscus equilibrium post-curing technique is employed. Two kinds of UV-curable resins, DentaClear and HEMA, were used for printing aspheric lenses in our experiments. The printed DentaClear lens featured low surface profile deviation of ~74 µm and showed satisfactory optical imaging resolution of 50.80 lp/mm, i.e., 4.92 µm. The surface roughness of the printed lens with DentaClear was measured to be around 2 nm with AFM. The surface roughness was improved as a result of post-curing, which reduced the ripples on printed lens surfaces. In contrast, the printed HEMA lens exhibited a significant stair-stepping effect with a large surface profile deviation of ~150 µm. The ripples were somewhat apparent even if the printed HEMA lens surface was smoothed by means of post-curing. No sharp image can be obtained with the HEMA lens in the resolution testing. The composition of HEMA resin may be the reason for the relatively poor surface quality and optical properties.