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Considering the escalating demand of lenses in various sectors, optical lens fabrication have got wide attention in present circumstances. Nevertheless, the structural complexity and precision were beyond the capabilities of conventional lens fabrication methodologies and hindered the time-efficient production. As a groundbreaking cutting-edge manufacturing technology, 3D printing has offered promising solutions for these difficulties and has showcased potential to produce multi-scale, multi-substrate and multi-functional lenses. Emerging printing techniques like FDM, SLA, DIW, Ink jetting and, TPP have demonstrated their potential in fabricating lenses using different materials and is found to be extensively used in eclectic range of applications. Synergizing post curing processes like meniscus equilibrium coating, rapid production of optical lenses with finer resolution and excellent surface smoothness is reported by advanced 3D printing techniques of Tomographic Volumetric Printing (TVP) and Micro Continuous liquid Interphase Printing (μCLIP) and a recent advancement in lens printing, zooming focused MIP-VPP technique, utilizing the frustum layer stacking can print complex lenses with reduced surface roughness and exceptional resolution without the requirement of post-curing. Elimination of staircase effect, printing characteristics and demonstration of commercial printing capability of the aforementioned techniques are discussed in this article. The review provides quantifiable data that illustrates the effectiveness of advanced 3D printing processes required for the production of optical lenses. For example, at 3.1 × 10⁴ mm³/h, Tomographic Volumetric Printing (TVP) obtained a surface roughness of 0.3340 nm, while Zooming-focused MIP-VPP yielded lenses with a roughness of 3.4 nm at 11.2 μm/s. Furthermore, the accuracy and effectiveness of these techniques were demonstrated by the fabrication of lenses using Micro-Continuous Liquid Interphase Printing (μCLIP) with an RMS roughness of 13.7 nm, a resolution of 1.32 μm, and a printing speed of 22.94 μm/s. By integrating features including high resolution, intricate geometry, and superior surface quality, these techniques help to enhance the advancements of complex optical devices, therefore making this discussion significant. |
