A small exit-pupil restricts the application of the Retinal Scanning Display (RSD) in the intelligent head-mount display (HMD). In this paper, we use the microlens array to solve this problem. A new thermal reflow process was designed and a circular-type microlens array with 70% fill factor in the form of a hexagonal close-packed arrangement by melting photoresist was prepared. The aperture size of every lens is 14μm and the period is 16μm. The gap is filled by a metal film to reflect off the beam which will not be modulated by the microlens. This achieves a more uniform exit-pupil expansion. We study the effect of different defects of the microlens array on the pupil expansion. The result shows that the NA and expansion angle of the microlens array are 0.38 and 45°, respectively.
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