Microlens array (MLA) has been widely used in optoelectronics field due to its characteristics of superior light extraction performance. However, most fabrication methods for MLA require heat or complicated processes and expensive equipment, which are not suitable for large-area, morphology-tunable MLA. This paper presents a new fabrication method for self-aligned MLA via multi-functional electrohydrodynamic (EHD) printing (direct-writing and drop-on-demand printing). The former creates a heterogeneously wettable surface for droplet self-aligning, and the latter precisely tune the droplet volume for MLA forming. This process is a versatile tool for MLA fabrication that inherits high resolution of EHD printing and morphology tunability from self-aligning process. By tuning the pattern of the confined zones and drop volume in each zone, MLA with different bottom shape, cell size, aspect ratio and filling factor have been generated, and their effects on light extraction have been discussed in detail. Finally, the self-aligned MLA with filling factor up to 99.3% reaches a light extraction enhancement of 49%, demonstrating their great potential in OLED light extraction.

微透镜阵列（MLA）具有出众的光提取性能，已被广泛用于光电领域。但是，大多数用于MLA的制造方法需要加热或复杂的过程以及昂贵的设备，因此不适合用于大面积，形态可调的MLA。本文提出了一种通过多功能电动流体动力学（EHD）印刷（直接书写和按需印刷）的自对准MLA的新制造方法。前者为液滴的自对准创建了一个非均质的可湿性表面，而后者则精确地调整了液滴的体积以形成MLA。此过程是用于MLA制造的通用工具，该工具继承了EHD打印的高分辨率和自对准过程的形态可调性。通过调整受限区域的模式和每个区域中的液滴体积，已经产生了具有不同底部形状，单元尺寸，长宽比和填充因子的MLA，并详细讨论了它们对光提取的影响。最终，填充系数高达99.3％的自对准MLA达到了49％的光提取增强性能，证明了它们在OLED光提取中的巨大潜力。