Fabrication and simulation of optical shaping diffuser to control light patterns

This study utilizes a 532 nm ps laser micromachining technique on Schott-B270 glass to fabricate micro-lens array (MLA) with optimized curvature and minimal surface roughness, aimed at achieving an optical shaping diffuser. The research demonstrates a two-step fabrication process that combines picosecond laser processing with wet etching, significantly enhancing optical diffusion. Square-shaped micro-lenses with diffusion angles ranging from 29° to 62° were successfully created, along with hexagonal and rectangular shapes. Optical simulations using LightTools, which employed built-in Bezier curves to design micro-lens parameters, analyzed the impact of micro-lens arrangements on light patterns. The simulations indicated that varying the spacing and overlap ratio of the micro-lenses influenced light intensity distribution, achieving uniform light patterns with intensity variations of less than 10 %. Experimental validation through optical measurements confirmed that the fabricated MLA produced well-defined light patterns, demonstrating their effectiveness for various optical applications. This work contributes to advancing the understanding of micro-lens fabrication techniques and their applications in enhancing light distribution.