This paper reports the fabricated method and optical performance of soft, reflective elements with nonspherical surface. Based on
excimer laser microdrilling and spin coating processes, a PMMA film suspended on microdrilled holes was used as a concave mold. Then,
a high-reflectance material, mixed PDMS rubber polymers with TiO2 nanoscale powders, was cast on the PMMA mold. Finally, both of
concave and convex elements could be fabricated through soft replica molding processes and these elements could directly reflect light
without the deposition of metal coatings. Therefore, we proposed a model regarding a flexible cable with its weight suspended on fixed
points to explain the formation mechanism of PMMA molds. With the change of diameters of microholes and thicknesses of PMMA
films, the suspended height of films was surely controllable. Therefore, the curvature radiuses and shapes of these aspherical elements also
depended on the diameters of microholes and the thicknesses of PMMA films. Experimental results demonstrated that soft reflective
elements have good surface qualities and high-quality optical properties. Besides, all fabrication steps can be executed in ambient environment
and at low temperature, the proposed method has a potential for mass production.
2007 Elsevier B.V. All rights reserved.
This paper reports the fabricated method and optical performance of soft, reflective elements with nonspherical surface. Based onexcimer laser microdrilling and spin coating processes, a PMMA film suspended on microdrilled holes was used as a concave mold. Then,a high-reflectance material, mixed PDMS rubber polymers with TiO2 nanoscale powders, was cast on the PMMA mold. Finally, both ofconcave and convex elements could be fabricated through soft replica molding processes and these elements could directly reflect lightwithout the deposition of metal coatings. Therefore, we proposed a model regarding a flexible cable with its weight suspended on fixedpoints to explain the formation mechanism of PMMA molds. With the change of diameters of microholes and thicknesses of PMMAfilms, the suspended height of films was surely controllable. Therefore, the curvature radiuses and shapes of these aspherical elements alsodepended on the diameters of microholes and the thicknesses of PMMA films. Experimental results demonstrated that soft reflectiveelements have good surface qualities and high-quality optical properties. Besides, all fabrication steps can be executed in ambient environmentand at low temperature, the proposed method has a potential for mass production. 2007 Elsevier B.V. All rights reserved.
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