A wafer-scale apparatus and method is described for the automation of
forming, aligning and attaching two-dimensional arrays of microoptic
elements on semiconductor and other image display devices, backplanes,
optoelectronic boards, and integrated optical systems. In an ordered
fabrication sequence, a mold plate comprised of optically designed
cavities is formed by reactive ion etching or alternative processes,
optionally coated with a release material layer and filled with optically
specified materials by an automated fluid-injection and defect-inspection
subsystem. Optical alignment fiducials guide the disclosed transfer and
attachment processes to achieve specified tolerances between the
microoptic elements and corresponding optoelectronic devices and
circuits. The present invention applies to spectral filters, waveguides,
fiber-optic mode-transformers, diffraction gratings, refractive lenses,
diffractive lens/Fresnel zone plates, reflectors, and to combinations of
elements and devices, including microelectromechanical systems (MEMS) and
liquid crystal device (LCD) matrices for adaptive, tunable elements.
Preparation of interfacial layer properties and attachment process
embodiments are taught.