Fabrication of optical microstructures on roller surface based on fast tool servo system

The optical microstructure on the roller surface is the key for manufacturing microstructures on optical film. In this context, the fabrication of optical microstructures on the cylindrical roller surface is more difficult than that on the planar surface. This Letter starts with a machinability of microstructure arrays on a cylindrical surface, and studies the restriction influences of the tool geometry and process parameters on the characteristics of the microstructure. Then a suitable flexible hinge holder for the fast tool servo is designed based on finite element analysis, and the influential factors to the machining precision of microstructure arrays are investigated. Finally, a machining test of spherical arrays on an aluminium cylindrical surface is carried out, and the high quality of the microstructure indicates that the proposed method is appropriate for the fabrication of optical microstructures.