The manufacture of lens arrays is required in optics for a number of reasons. It can have the goal of installing the entire array directly into the optical system (e.g. slow-axis collimators for high-performance diode lasers) or it may be used as a wafer-based optics carrier in which the individual lenslets are separated after molding using separating processes. One solution has already been developed in which a multi-axis ultra-precision grinding process can be used to produce a series of individual indentations in hard metal. For spherical forms, irregularities of < 150 nm PV/lenslet and surface roughnesses of Ra < nm have already been improved upon. Such molding tools can then be used to mold lens arrays in numerous types of high-refractive glasses. Aspherical lens arrays can also already be produced with this method, although the accuracy that can be achieved is still being evaluated.

