A Micro-lens Array (MLA) is an optical element in which multiple lens segments are integrated onto a single substrate. Traditional MLAs consist of segments with the same geometric shape arranged at regular intervals atop a planar surface. They are used for applications that include beam homogenization, to equalize light intensity distribution, and light field imaging to change post-exposure the optical configuration such as viewpoint and focal distance of the captured image data. However, the limitations imposed by the identical segment geometry and the regular arrangement pattern constrain the range of possible applications and their associated performance. In this paper, novel MLA geometries and design methods are introduced that enable new generation products. With this type of MLA, each segment can have a different free planar shape and freeform surface shape in height direction. The segments of MLA are designed with topology optimization method based on internal stresses, that allows unsupervised design of optical segments. The designed freeform segments can maximize the use of light the lens, according to the target illumination pattern and intensity defined by each segment.
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