Fabrication of Lens Array Using a 3D Printer and Vacuum Forming

In this study, we used a 3D printer, vacuum forming, and soft molding methods to fabricate a lens array. We printed the first prototype of the lens array using a 3D printer. Then, we used vacuum forming to smooth the surface of the prototype with a melted plastic sheet. Subsequently, the smoothed prototype was used to create a soft mold using polydimethylsiloxane. We poured thermal epoxy into a soft mold and allowed it to harden, forming transparent epoxy lens arrays. The fabricated lens array produced good images of objects and exhibited excellent lens performance. Furthermore, the focal length of the lens arrays was varied by adjusting the radius of curvature of the prototype. The proposed fabrication approach offers the potential for students to create their lenses and practice optical theory.