Low-Cost, High-Volume Replication of Durable Non-PLastic Diffractive Elements for UV and Visible Applications

Diffractive optics is a promising technology for the aberration correction, athermalization, and achromatization of imaging systems. Diffractive optical elements (DOEs) can also be used for the generation of fanout arrays, microlens arrays, anti-aliasing gratings, and polarization optics. Applications include the fabrication of sports and military optics such as light-weight binocular eyepeices and rifle scopes, optical interconnects for communication systems, DOEs for HMDs, and fanout arrays for laser machining. In order to capitalize upon the advantages diffractive optics has to offer over conventional optics, the technology for manufacturing high-quality, low-cost DOEs needs to be developed. During Phase I we plan to investigate a novel method of fabrication durable diffractive optics replicas. Currently, developed replication technologies result in a final diffractive surface that is polymer-based. For applications involving high temperatures, long-term durability, or applications in the UV spectral region, plastic materials are not suitable. The replication method we will investigate results in durable DOEs fabricated in substrated materials such as SiO2. Unlike current fabrication processes whereby each element must be individually pattered via diamond turning or photolithographic techniques, the proposed replication method requires only a single master element to be fabricated in this manner. Subsequent SiO2 elements are replicated from this master, resulting in lower element cost and in replicas that are durable and suited for multiple dual-use applications in the UV and visible regions of the spectrum. Anticipated Military Benefits/Potential Commercial Applications of the Research or Development: Non-plastic DOE replicas have dual-use applications in the UV and visible spectral regions. Applications include UV lithography, laser machining, lightweight binocular eyepeices, and zoom lenses for camcorders.