Abstract:
A method for making microlens and microlens array is described which utilizes a spinning half radius diamond cutting member operated in a plunge cut in a technique similar to milling to cut the optical surface into a diamond turnable material. The method can be used to make high sag lens molds with high accuracy. Microlens array molds can be made with a high degree of uniformity and a nearly 100% fill factor.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is related to U.S. application Ser. No. 09/702,952, filed herewith, by John Border, et al., and entitled, “Method Of Manufacturing A Microlens Array Mold And a Microlens Array;” U.S. application Ser. No. 09/702,362, filed herewith, by John Border, et al., and entitled, “Apparatus For Forming A Microlens Mold;” U.S. application Ser. No. 09/702,500, filed herewith, by John Border, et al., and entitled, “Apparatus For Forming A Microlens Array Mold;” U.S. application Ser. No. 09/702,402, filed herewith, by John Border, et al., and entitled, “Method For Making A Microlens Mold And A Microlens Mold;” U.S. application Ser. No. 09/702,496, filed herewith, by John Border, et al., and entitled, “Apparatus And Method For Making A Double-sided Microlens Mold And Microlens Array Mold;” and, U.S. application Ser. No. 09/702,302, filed herewith, by John Border, et al., and entitled, “Double-Sided Microlens Array.” 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to the field of improved microlens molds and microlens. More particularly, the invention concerns a method of making a precision mold suitable for forming high quality, micro-sized optical articles, such as a microlens or microlens array. 
     BACKGROUND OF THE INVENTION 
     Rotationally symmetric optical surfaces in molds for injection molding or compression molding are typically made either by grinding or diamond turning. While these techniques work well for larger surfaces, they are not suited for making high quality optical surfaces in small sizes or arrays. Other techniques are available for making small scale single lenses and arrays but they are limited as to fill factor, optical accuracy and/or the height or sag of the lens geometry that can be made. 
     Grinding relies on an orbital motion of the grinding surfaces to make a precision optical surface without scratches. However, the orbital motion and the grinding surfaces become impractical when making optical surfaces below a few millimeters in size. Grinding multiple surfaces for an array can only be done one surface at a time with multiple pieces that are then fit together. 
     Diamond turning can be used to make optical surfaces down to 2 millimeters in size but the setup is difficult. Precise location of multiple optical surfaces is not possible due to multiple setups. The need for multiple setups also increases the machining time for an array so that diamond turning becomes cost prohibitive. 
     Another technique that is suitable for making microlenses under 2 millimeters is polymer reflow. Polymer reflow is done by depositing drops of polymer onto a surface and then heating the polymer to allow it to melt and reflow into a spherical shape under the influence of surface tension effects. In order to obtain a truly spherical optical surface, reflow lenses must be separated from one another so that they contact the underlying surface in a round pattern. To maintain round pattern of each lens at the surface, the lenses must be separated from one another which substantially limits the fill factor in an array. U.S. Pat. No. 5,536,455, titled, “Method Of Manufacturing Lens Array,” by Aoyama, et al., Jul. 16, 1996, describes a two step approach for making reflow lens array with a high fill factor. Using this technique, a second series of lenses is deposited in the gaps between the first set of lenses. While this technique can provide a near 100% fill factor, the second set of lenses does not have round contact with the underlying surface so that the optical surface formed is not truly spherical. Also, reflow techniques in general are limited to less than 100 microns sag due to gravity effects. Aspheric surfaces cannot be produced using polymer reflow. 
     Grayscale lithography is also useable for making microlenses under 2 millimeters. Grayscale lithography can be used to make nearly any shape and high fill factors can be produced in lens arrays. However, reactive ion beam etching and other etching techniques that are used in gray scale lithography are limited as to the depth that can be accurately produced with an optical surface, typically the sag is limited to under 30 micron. 
     High sag lenses are typically associated with high magnification or high power refractive lenses that are used for imaging. High power refractive lenses have tight curvature and steep sides to maximize the included angle and associated light gathering or light spreading which implies a high sag. In the case of image forming, refractive lenses are preferred to preserve the wave front of the image. In other cases such as illumination where the wave front does not have to be preserved, Fresnel or diffractive lenses where the optical curve is cut into segmented rings, can be used to reduce the overall sag of the lens. In the case of microlenses, high power diffractive lenses are not feasible due to the steepness and narrow spacing of the ring segments at the edge that would be required to make a low sag, high power microlens. 
     U.S. Pat. No. 5,519,539, titled, “Microlens Array With Microlenses Having Modified Polygon Perimeters,” by Hoopman et al., May 21, 1996 and U.S. Pat. No. 5,300,263, titled, “Method Of Making A Microlens Array And Mold,” by Hoopman et al., Apr. 5, 1994, describe a method for making lens arrays that involves casting a polymer into a series of small receptacles so that surface tension forms the polymer surfaces into nearly spherical shapes. A correction is done on the shape of the receptacles to make the surfaces more closely spherical but this results in football-shaped intersections so that optical quality and the effective fill factor are limited. 
     Therefore, a need persists in the art for a method of making a precision microlens mold suitable for forming high quality, micro-sized optical articles, such as a microlens or a microlens array. 
     SUMMARY OF THE INVENTION 
     It is, therefore, an object of the invention to provide a method of making a precision mold for microsized optical articles. 
     Another object of the invention is to provide a method of making a precision mold that does not damage the mold surface. 
     Yet another object of the invention is to provide a method of making a mold that utilizes a cutting member that is not limited to depth of penetration. 
     Still another object of the invention is to provide a method of making a precision mold that is useable for forming an array of micro-sized optical articles. 
     It is a feature of the invention that a forming element having a high speed, rotatable half-radius diamond cutting member rotatably engages a substrate in a predetermined cutting pattern to form a precision mold surface in the substrate. 
     According to one aspect of the present invention, a method of manufacturing a microlens, comprising the steps of: 
     (a) forming a microlens mold cavity, said forming includes milling a substrate with a hardened cutting member such that said microlens mold cavity has a predetermined configuration; 
     (b) injecting a molten polymeric material into said microlens mold cavity; and, 
     (c) hardening said molten polymeric material in said microlens mold cavity thereby forming a microlens having a predetermined configuration. 
     In another aspect of the invention, a microlens and a microlens array made by the method of the invention has a spherical shaped surface, an aspheric shaped surface or an anamorphic shaped surface. 
     The present invention has the following advantages: the precision microlens mold can be used to mold high quality, micro-sized optical articles, such as microlenses, that have symmetric surfaces with steep sides and high sags; and, the forming element is contoured to produce very accurate optical surfaces in single microlenses or arrays. In the case of arrays, near 100% fill factor can be achieved in the molded article. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects, features, and advantages of the present invention will become more apparent when taken in conjunction with the following description and drawings wherein identical reference numerals have been used, where possible, to designate identical features that are common to the figures, and wherein: 
     FIG. 1 is a perspective view of the substrate of the invention having a plurality of square microlens mold cavities; 
     FIG. 2 is a perspective view of the substrate having a plurality of hexagonal mold cavities formed by the method of the invention; 
     FIG. 3 is a perspective view of the substrate having a plurality of random mold cavities formed by the method of the invention; 
     FIG. 4 is a perspective view of an upright spherical cutting member for forming a precision microlens mold; 
     FIG. 5 is a perspective view of an aspheric cutting member of the invention; 
     FIG. 6 is a perspective view of the apparatus of the invention for forming a single microlens mold; 
     FIG. 7 is a perspective view of the apparatus of the invention for forming a microlens array mold; 
     FIG. 8 is an enlarged perspective view of the forming element of the invention showing a clearance in mold cavity; 
     FIG. 9 is a perspective view of a two-sided microlens mold made by the method of the invention; 
     FIG. 10 is an enlarged perspective view of a microlens array mold mounted for use in a mold base for injection molding or compression molding; and, 
     FIG. 11 is a perspective view of an apparatus for making a double-sided microlens. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Turning now to the drawings, and in particular to FIGS. 1-3, improved microlens molds  10 ,  16 ,  20  made by the method of the invention are illustrated. According to FIG. 1, microlens mold  10  has a plurality of interconnecting square intersection micro-sized mold cavities  12  formed in substrate  14 , as described more fully below. In FIG. 2, microlens mold  16  has a plurality of interconnecting hexagonal shaped intersection micro-sized mold cavities  18  formed in substrate  14 , also described more fully below. Alternatively, according to FIG. 3, microlens mold  20  has either a single microsized mold cavity (not shown) or a plurality of randomly distributed micro-sized mold cavities  22  formed in substrate  14 , as described below. Substrate  14 , in which the precision microlens molds  10 ,  16 ,  20  of the invention are formed, may be made of any material that is compatible with very hard cutting tools, such as a diamond milling tool. In the preferred embodiment of the invention, substrate  14  includes materials selected from among copper, nickel, nickel alloy, nickel plating, brass, and silicon, with hardened nickel plating being most preferred. 
     Referring to FIGS. 4 and 5, microlens mold  10 ,  16 ,  20  have been developed using the novel diamond milling method of the invention. As shown in FIG. 4, a spherical forming element  24  having a half radius diamond cutting member  26  is used to form the mold cavities  12 ,  18 ,  22  in the respective substrate  14  of microlens mold  10 ,  16 ,  20 , by diamond milling into substrate  14 . Diamond cutting member  26  has a substantially planar first face  28 , a substantially planar second face  30  orthogonal to and intersecting first face  28 , and a spherical contoured shaped cutting face  32  intersecting both the first and second face  28 ,  30  (respectively). First face  28  defines the rotational axis  34  of diamond cutting member  26  when operably connected to control member  36  and affixed for milling substrate  14 , described below. Forming element  24  may be used to form a spherical microlens mold  10 ,  16  or  20  in substrate  14  (FIGS.  1 - 3 ). Spherical microlens mold  10 ,  16  or  20  is used for making spherical microlens articles. 
     According to FIG. 5, an alternative aspheric forming element  40  has an aspheric diamond cutting member  41 . Diamond cutting member  41  has a substantially planar first face  42 , a substantially planar second face  46  orthogonal and intersecting first face  42  and an aspheric cutting face  44  adjoining both first and second face  42 ,  46  (respectively). First face  42  defines the rotational axis  49  of diamond cutting member  41  when operably connected to control member  48  and affixed for milling substrate  14 , described below. Forming element  40  having control member  48  may be used to form an aspheric microlens mold  10 ,  16  or  20  in substrate  14  (FIGS.  1 - 3 ). Aspheric microlens mold  10 ,  16  or  20  is used for making aspheric microlens articles. 
     Referring to FIG. 6, in another aspect of the invention, apparatus for forming a precision single microlens mold (of the type shown in FIGS. 1-3) for a micro-sized optical article includes a forming element  24  or  40  operably connected to tool holder  56  and rotating control member  58 . Forming element  24  or  40  has a rotatable hardened cutting member  26  or  41 , preferably diamond (shown clearly in FIGS.  4  and  5 ), fixedly aligned relative to a linearly displaceable (noted by arrow Z) substrate  14 . Substrate  14 , operably connected to control member  64 , is arranged for movement towards and away from hardened cutting member  26  or  41 , as described above. Control member  36  or  48 , forming element  24  or  40 , and control member  64  are preferably all parts of a precision air bearing lathe such as is available from Precitech, Inc., located in Keene, N.H., which is expressly designed for diamond turning of high precision parts. In this embodiment, apparatus  50  can mill a predetermined shaped single microlens mold  52  in the substrate  14 . Platform  54  is used to provide a solid, non-vibrating base for supporting apparatus  50  with both forming element  24  or  40  and substrate  14  during the mold forming process. 
     Referring to FIGS. 6 and 7, substrate  14  is preferably mounted for movement relative to fixed forming element  24  or  40 . According to FIG. 6, apparatus  50  forms a single microlens mold  52  in substrate  14 , as discussed above. In FIG. 7, however, apparatus  60  has a substrate  14  mounted for three-dimensional movement for forming a microlens mold array  62 . Flexibly moveable substrate  14  is operably connected to control member  64  that governs the movements of substrate  14 . The control member  64  in this case preferably has the ability of precision controlled movement of substrate  14  in the directions X-Y-Z as indicated in FIG.  7 . Precision air bearing lathes with precision X-Y-Z table movement are available from Precitech, Inc., located in Keene, N.H. The X-Y-Z table movement of control member  64  is used to produce the flexible movements of substrate  14  relative to forming element  24  or  40 . A tool holder  56  fixedly attached to rotating control member  58 , such as the ones described above, having diamond cutting member  26  or  41  (as described above) is positioned for milling microlens array mold  62  in substrate  14 . By having a movable substrate  14 , an array of microlens mold cavities can be formed in substrate  14 . Movable substrate  14  is first positioned to mill one of a plurality of microlens mold cavities  62   a  in the microlens array mold  62 . After forming the one of a plurality of microlens mold cavities  62   a , forming element  24  or  40  is removed from the mold cavity  62   a  and then the substrate  14  is moved laterally (X-Y) by control member  64  to another position for forming another microlens mold cavity  62   b . This procedure is repeated until the desired number of microlens mold cavities in the microlens array mold  62  is formed in substrate  14 . Thus, by repeating these steps, apparatus  60  having a movable substrate  14  can produce a high quality microlens array mold  62 , such as those illustrated in FIGS. 1-3. 
     Those skilled in the art will appreciate that any rotationally symmetric optical surface, such as a microlens surface, can be produced in the manner described. Spherical surfaces are produced using a half radius diamond with a circular segment diamond. Aspheres can be produced by using a diamond with an aspheric cutting edge. 
     Moreover, some rotationally non-symmetric lens surfaces, such as anamorphic surfaces, can be made using a modified version of the technique described. In this case, the diamond tooling is moved laterally during the cutting action to create an elongated version of the spherical or aspheric surface. 
     Skilled artisans will appreciate that in order to obtain a high quality lens surface, it is important to follow some basic machining concepts. To minimize the center defect in the lens surface produced, it is important to center the diamond cutting member  26  or  41 , as shown in FIGS. 4 and 5. The quality of microlens mold  10 ,  16 ,  20  is best achieved if the axis of rotation  34  or  49  of diamond cutting member  26  or  41  (respectively) is centered to better than 5 microns relative to the axis of rotation (not shown) of the tool holder  56  in rotating control member  58  (FIGS.  6  and  7 ). Also, the tool holder  56  must be balanced to eliminate vibration to minimize chatter. Solid platform  54  helps to promote stability of apparatus  50  and  60  during operation. Further, the right combination of diamond cutting member  26  or  41  rotational speed, feed, i.e., the rate that diamond cutting member  26  or  41  penetrates substrate  14 , and lubrication must be used to obtain the cleanest cut. Moreover, according to FIG. 8, forming element  24  or  40 , shown with diamond cutting member  26  or  41  (similar to those described), must be produced in such a manner that a sufficient clearance  70  is provided on the back side  72  of the diamond cutting member  26  or  41  to avoid drag marks on substrate  14 . Drag marks (not shown) typically result from interference of the backside  72  of diamond cutting member  26  or  41  with the substrate  14  during the formation of microlens mold  76 . 
     By using the method of the invention, spherical microlens molds have been made down to 30 microns in diameter with irregularity of better than 0.50 wave (0.25 micron). Further, microlens mold arrays have been made up to 80×80 microlenses with a 250 micron pitch in an orthogonal layout and a near 100% fill factor. 
     Moreover, it should be appreciated that the repeated milling process of the invention (FIG. 7) is well suited for making accurate microlens arrays. Since the process for making each microlens in the array is unconnected to the other lenses in the array, a nearly 100% fill factor can be obtained in the array. 
     Furthermore, aspheric lens surfaces can also be produced using this technique. In this case, an aspheric diamond cutting member  41  (FIG. 5) is all that is required to make rotationally symmetric aspheric lens surfaces. Anamorphic lens surfaces can be made as well using a modified version of this technique. In this case, the same or similar diamond cutting member  41  is moved laterally during the cutting operation to produce an elongated lens surface. 
     The precision molds  10 ,  16 ,  20  (FIGS. 1-3) made with the methods and apparatus  50  or  60  of the invention, can be used to manufacture large numbers of optical articles, such as microlenses. Generally, injection molding and compression molding are the preferred molding methods for forming the typically glass or plastic microlenses. In some cases casting is the preferred method. 
     Referring to FIGS. 9 and 11, the apparatus used for injection molding or compression molding of plastic microlenses using the microlens molds mounted into a mold base is illustrated. Apparatus for molding a two-sided microlens array  80  is composed of two large blocks or mold bases  82  each having an active molding face  83 . Mold bases  82  are comprised typically of steel or other metal. Alignment members arranged on molding faces  83  include guide pins  88 , tapered locating bushings  86  and corresponding apertures (not shown) for receiving guide pins  88  and tapered locating bushings  86 . The microlens molds  84  and the mold cavities  85  were made according to the methods and apparatus of the invention. Referring to FIG. 11, in operation, the apparatus  80  comprises mold bases  82  which are installed into one of two platens  104 ,  106  of a hydraulic, pneumatic or electrically driven press  108 . One side of the apparatus  80  is connected to one platen  104  of the press  108  and the other side is connected to the other platen  106 . When the press closes, the guide pins  88  help to align the two sides of the mold base  82 . At the final closing, the tapered locating bushings  86  align the two sides of the mold base  82  and the microlens molds  84  with each other. In the case of molding a two-sided microlens array, it is very important that the microlens surfaces on the opposing sides are aligned with each other. To aid with the alignment of the opposing microlens surfaces in each of the sides of the mold base  82 , the microlens molds  84  are typically made on square substrates  100  (as shown in FIG. 10) so that they cannot rotate in the mold base  82 . 
     In the case of injection molding, after the press and mold base have been closed, molten plastic is injected under pressure into the mold cavity. After the plastic has cooled in the mold to the point that it has solidified, the press and mold base are opened and the molded microlens array is removed from the mold. 
     In the case of compression molding, prior to the press closing, a hot plastic preform is inserted into the heated mold cavity. The press and mold base is then closed which compresses the plastic preform and forms the plastic to the shape of the mold cavity and microlens array mold. The mold and plastic is then cooled, the press and mold base is opened and the molded microlens array is removed from the mold. 
     In an alternate case in which a one-sided microlens array or single microlens is being injection or compression molded, the opposing side from the microlens mold is typically a plano surface and then, since side-to-side and rotational alignment is not an issue, the microlens mold may be made onto a round substrate. 
     FIG. 10 shows the microlens array mold  96  (also shown in FIG. 9) with a square substrate  100  as is typically used to prevent rotation of the microlens array mold surface  98  in the mold base  82  of apparatus  80 . The microlens array mold surface  98 , the depth of the mold cavity  85  and the thickness of the molded microlens array article are determined precisely by adjusting the overall height of the substrate  100  and the height of the larger round substrate  102  on the bottom of the substrate  100 . 
     In cases where casting is the preferred method of production, the material is simply poured into the mold cavity and allowed to solidify by chemical reaction rather than cooling. After the part has solidified, the part is removed from the mold. 
     It is our experience that microlens molds made according to the invention have been used to injection mold microlens surfaces in which the sag is not limited, as indicated below. Further, near hemispheric lenses can be produced with very steep sidewalls. Also, it is our experience that optical surfaces can be machined directly into mold materials such as nickel, copper, aluminum, brass, nickel plating, or silicon. 
     Since apparatus  50 ,  60  having a forming element  24 ,  40  with diamond cutting member  26 ,  41  (respectively) is quite accurate, it is our experience that lens surfaces can be produced in sizes down to 10 micron or less in diameter and 2 micron sag. Lenses up to 25 in diameter are also possible with sags of over 12.5 mm. 
     The following are several exemplary examples of microlenses made with the method and apparatus of the invention. 
     EXAMPLE 1 
     A microlens array mold with 80×80 microlenses was made in aluminum. The half radius diamond tool was obtained from ST&amp;F Precision Technologies and Tools, located in Arden, N.C. The microlens surfaces were 0.250 mm across positioned in a square intersection array. The microlenses surfaces were spherical in curvature with a radius of 0.500 mm and a sag of 33 micron. Referring to FIG. 4, centering of the diamond cutting member  26  in the control member  36  was done using an iterative process where a test cut was examined under the microscope and adjustments of the location of diamond cutting member  26  were made based on the size of the center defect. Rotational speed of diamond cutting member  26  used was about 1000 rpm. Cutting fluid was purified mineral oil. The result of this process was a center defect of the machined mold of 2 micron and surface irregularity of 1 Wave (0.5 micron). Parts were subsequently injection molded, using the machined mold surface, to produce polymethylmethacrylate microlens arrays. 
     EXAMPLE 2 
     Similar to Example 1 with the exception that a hardened nickel-plated substrate was used for the machined mold surface. 
     EXAMPLE 3 
     A microlens array mold with 13×13 microlenses surfaces was made in a hardened nickel-plated substrate. The microlens surfaces were 1.30 mm across positioned in a square intersection array. The half radius diamond tool was obtained from ST&amp;F Precision Technologies and Tools, located in Arden, N.C. The microlens surfaces were spherical in curvature with a radius of 3.20 mm and a sag of 213 micron. Centering and the machining process were the same as described in Example 1. The result was a center defect of 1.5 micron with a surface irregularity of 0.30 Wave (0.15 micron). 
     EXAMPLE 4 
     A series of single microlens surfaces was made in a 715 nickel alloy substrate. The microlens surfaces all were made with a 0.500 mm radius diamond tool. Diameters varied from 0.062 mm to 0.568 mm. The machining process was similar to that described in Example 1. 
     EXAMPLE 5 
     A larger microlens array of 63.5×88.9 mm was made with 21,760 microlenses in total in a 125×175 square intersection array. A diamond half radius tool with a 0.5008 mm radius was used, obtained from Chardon Tool, Inc., located in Chardon, Ohio. The array was made with a 0.50932 pitch and a 0.16609 sag. The substrate was nickel-plated steel. The machining process was similar to that described in Example 1. 
     EXAMPLE 6 
     It is also within the contemplation of the invention that by machining matched optical surfaces for a mold, two-sided microlens arrays can be molded in large numbers. According to FIG. 9, two matched microlens array surfaces were made in hardened nickel-plated substrates. The half radius diamond tool or diamond cutting member  26  (FIG. 4) was obtained from Contour Fine Tooling, Inc., located in Marlborough, N.H. The microlens surfaces were made with a 1.475 mm radius and a 0.750 mm pitch in a square intersection pattern, the sag was 99 micron. The machining process was similar to that described in Example 1. A center defect of 2 micron and an irregularity of 0.3 Wave (0.15 micron) were achieved in the machined surface. In this case, the two matched microlens array surfaces were mounted in a mold base so that they were opposed. To align the microlens surfaces on each side, the microlens surfaces were machined into square substrates prior to mounting into a mold base thereby inhibiting rotational misalignment. Taper lock bushings were then used to prevent lateral misalignment. Following this process, two-sided microlens arrays were injection molded from polymethylmethacrylate. The molded microlenses on the two-sided array were aligned with each other within 30 micron. 
     The invention has been described with reference to a preferred embodiment. However, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention. 
       10  microlens mold with square intersections 
       12  mold cavity with square perimeter 
       14  substrate 
       16  microlens mold with hexagonal intersections 
       18  mold cavity with hexagonal perimeter 
       20  microlens mold with randomly distributed microlenses 
       22  randomly distributed mold cavities 
       24  spherical forming element 
       26  spherical diamond cutting member 
       28  first face of diamond cutting member  26   
       30  second face of diamond cutting member  26   
       32  spherical contoured cutting face of diamond cutting member  26   
       34  rotational axis of diamond cutting member  26   
       36  control member for diamond cutting member  26   
       40  aspheric forming element 
       41  aspheric diamond cutting member 
       42  substantially planar first face of aspheric diamond cutting member  41   
       44  aspheric cutting face of aspheric diamond cutting member  41   
       46  substantially planar second face of aspheric diamond cutting member  41   
       48  control member for diamond cutting member  41   
       49  rotational axis of diamond cutting member  41   
       50  apparatus for forming a precision single microlens mold 
       52  single microlens mold 
       54  platform 
       56  tool holder for forming element  24  or  40   
       58  rotating control member 
       60  alternative embodiment of apparatus for making microlens array molds 
       62  microlens array mold 
       62   a  single microlens mold cavity 
       62   b  another single microlens mold cavity 
       64  control member 
       70  clearance 
       72  backside of diamond cutting member 
       76  microlens mold 
       80  apparatus for molding a two-sided microlens array 
       82  mold base 
       83  active molding face 
       84  microlens molds 
       85  mold cavities 
       86  tapered locating bushings 
       88  guide pins 
       96  microlens array mold 
       98  microlens array mold surface 
       100  square substrate 
       102  round substrate 
       104  platen 
       106  platen 
       108  press