Microreplicated Optical Structures
There is a wide range of different micromachining techniques that are suitable for mastering. Processes like anisotropic and isotropic wet etching as well as deep reactive ion etching (DRIE) in silicon wafers are used routinely. Other frequently used IC-based lithography processes for mastering are e-beam, laser and ultraviolet (UV) lithography of thick resists. In addition, sophisticated conventional workshop tools, for example micromilling and micro-electro discharge machining (EDM), are important complementary techniques in order to fabricate micromold inserts with an interface to the macroscopic world.
Replication in polymeric materials
Micro replication in polymers is a new technology that makes possible cost-efficient, high volume production of microstructures. The technique is essentially identical with the method of fabricating CDs. Many of our LGP products are produced by this method by world leading CD makers. First a master (original structure) is produced, then a mold insert is made by electroplating and finally replicas are made through injection molding. In order to achieve high precision microstructures the master is made by silicon micromachining, using high precision lithography and etching technologies. Nickel is then electroplated on the structured silicon surface to act as a mould insert.
Proprietary Rapid Prototyping
In most cases of new LGP design there is a need to go through several iterative solutions. Production of masters would place a significant financial burden and require a long leading time. Visus offers a number of proprietary rapid prototyping techniques with considerably reduced NRE costs along with an optical design or optimization of your application.
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