Manufacturing of molds by multiphoton polymerization for micro-replication of optically enhanced surfaces

Freeform and microstructured features are generated by MultiPhoton Polymerization with an ultrafast laser, on tool-steel inserts, for microreplication of optical surfaces. The generation of optical surfaces has been studied by combining laser machining and multiphoton polymerization techniques. Resolution in the range of few microns, down to 300 nm lateral dimension, has been targeted on the optically enhanced surfaces. The microstructured surfaces have been further replicated by injection molding on polymer components of several cm(2). The fabrication accuracy and precision has been evaluated in terms of lateral and vertical resolution of the laser generated features, and the replicated ones. The technology aims to simplify the assembly routes for heterogeneously integrated optoelectronics through direct overmolding of the optics on the components (transceivers, LEDs or sensors), with drastic improvements in cost, productivity and performance.