High-Speed 3D Printing of Millimeter-Size Customized Aspheric Imaging Lenses with Sub 7 nm Surface Roughness

Advancements in three-dimensional (3D) printing technology have the potential to transform the manufacture of customized optical elements, which today relies heavily on time-consuming and costly polishing and grinding processes. However the inherent speed-accuracy trade-off seriously constrains the practical applications of 3D-printing technology in the optical realm. In addressing this issue, here, a new method featuring a significantly faster fabrication speed, at 24.54 mm³ h⁻¹, without compromising the fabrication accuracy required to 3D-print customized optical components is reported. A high-speed 3D-printing process with subvoxel-scale precision (sub 5 µm) and deep subwavelength (sub 7 nm) surface roughness by employing the projection micro-stereolithography process and the synergistic effects from grayscale photopolymerization and the meniscus equilibrium post-curing methods is demonstrated. Fabricating a customized aspheric lens 5 mm in height and 3 mm in diameter is accomplished in four hours. The 3D-printed singlet aspheric lens demonstrates a maximal imaging resolution of 373.2 lp mm⁻¹ with low field distortion less than 0.13% across a 2 mm field of view. This lens is attached onto a cell phone camera and the colorful fine details of a sunset moth's wing and the spot on a weevil's elytra are captured. This work demonstrates the potential of this method to rapidly prototype optical components or systems based on 3D printing.