Rapid Direct Laser Writing of Microoptical Components on A Meltable Biocompatible Gel

Microoptical components are coming of age in a wide range of applications: lab-on-a-chip, imaging, detection... There are a large number of fabrication technologies capable of producing high quality individual components and their arrays. However, most of them require high-end and costly equipment, complex and time-consuming fabrication, harmful chemicals, resulting in expensive final products. Here we present a technology capable of producing high quality microoptical components, using low-end direct laser writing on a biocompatible, environmentally friendly hydrogel, without any waste substances. Gel is locally and controllably melted while surface tension forces shape the optical component, following the laser beam profile. Process is so quick that a single microlens is fabricated in less than a second, and can be used instantly without any further processing. The technology is neither subtractive nor additive, and the base material is simply displaced producing a smooth surface. We have been able to fabricate individual microlenses and their arrays (positive, negative, aspheric), gratings and diffractive components. The technology is tested by generating unique, difficult to counterfeit QR-codes. Turnaround time is fast and makes the technology suitable both for rapid prototyping and serial production.