Micro-Prism Arrays: Femtosecond Laser Processing as the New Standard for LGP Molds

The Manufacturing Bottleneck

For high-precision injection molding—specifically for structures under 50μm—traditional methods like screen printing or standard CNC milling struggle to achieve the required sharpness and geometric consistency. As displays move toward thinner, high-brightness form factors, the mold itself must possess an extreme degree of structural sharpness and positional accuracy.

Why Femtosecond Laser is the Ideal Tool for LGP Molds

Femtosecond laser micromachining is the industry-preferred solution for high-precision LGP mold fabrication. Unlike thermal-based laser processing, femtosecond "cold ablation" allows for sub-micron material removal, directly forming complex pits and channels on hardened mold steel with unmatched precision.

MONO’s Expertise in Complex Optical Micro-Structures

At MONO, we have successfully tackled the most complex mold micro-structure geometries required for next-gen display tech:

• Geometry Versatility: V-grooves, semi-circular troughs, honeycomb pits, and meniscus-shaped indentations.
• Sub-10μm Precision: Micro-structures as small as 10μm, with dimensional accuracy of ±1μm and positional accuracy of ±1μm.
• Dynamic Density Control: We can digitally vary the micro-structure density across the mold surface, allowing for sophisticated light-path design that optimizes overall luminance uniformity.

Looking Forward: New Materials, New Possibilities

Optical quality is defined by the design, but its execution is limited by the manufacturing process. As the industry trends toward ultra-thin, high-brightness, and flexible display technologies, MONO’s femtosecond laser platform offers the material adaptability needed for high-performance resins and advanced optical glass. By providing efficient prototyping and high-precision validation, we are enabling the next generation of optical components.