Fabrication of curved MLA-grating based on 3D printing mold and vacuum-assisted deformation replication process

The combination of Microlens Array (MLA) with a grating structure is an effective means of improving light shaping efficiency due to the light dispersion effects of both elements. This paper proposes an innovative method for fabricating a curved MLA-grating composite element using a 3D printing mold and vacuum-assisted deformation replication process. In addition to the cost advantages of the process, the optical parameters such as type and line-density of grating, curvature and aperture size of the microlens can be effectively controlled, so as to bring different diffraction and focusing effects. Test results demonstrate that the curved MLA-grating element has superior light dispersion efficiency, making it useful in improving the illumination range of light sources. Additionally, due to the focusing effect of the curved substrate, this element holds promise for enhancing the light energy utilization rate in the photovoltaic field.