Reconfigured multi-axis diamond shaping of complex monolithic optics

Monolithic optics are rapidly developing to fulfil the increasing demand for smart imaging. The complexity of such optics makes it almost impossible to fabricate directly using multi-axis machining. The industry is urging for a versatile solution, despite various techniques tailored for specific microstructures. In this paper, a novel multi-axis approach is proposed to directly develop maximum fill-factor complex lens arrays with intricate features, by reconfiguring the multi-axis to expand flexibility to develop these functional surfaces. The effectiveness of this approach is experimentally verified. This study paves a way towards versatile solutions to address any complex surface currently considered “impossible to machine”.