Gallium and polydimethylsiloxane molding for self-organized spherical lens surface fabrication

We present a new fabrication method for optical surfaces using liquid metal molding. Common optical surfaces are fabricated by the polishing of glasses or plastics. By contrast, the fabrication method we propose involves the transfer of a spherical surface of liquid molded metal with silicone rubber. The concept presented in this paper is of a new molding method in which a mold is placed inside. The curvature can be controlled from similar to 0.37 mm(-1) to -0.37 mm(-1) by wetting the liquid metal. An application of this method is to produce on-demand optical elements (e.g., lenses and mirrors). (c) 2017 Optical Society of America