A polymer mems mirror for on-demand light distribution fabricated by injection molding and transfer of printed layers

A high-throughput and low-cost fabrication process for an optical microscanner is proposed for lighting applications. The process utilizes mold replication and transfer of printed functional layers to form a film. We confirmed that a high-throughput fabrication lasting less than 30 s could be obtained by using a mold with a knife edge. A polymer microscanner with feature size of 0.6 × 2 mm2 was successfully fabricated using our process. The scanner was actuated by magnetic forces generated by an external coil, and the mirror tilt angle was successfully measured by a strain gauge formed by the functional layer transfer. By synchronizing the LED input signal and the polymer scanner tilt angle, the illuminance distribution could be controlled. For example, this distribution could be expanded from 10° to 50° or divided into two separated spots. We believe that our developed process can address new MEMS applications such as commercial lighting.