Hello,

I am currently modeling a microlens array like this, and here is my solution using boolean operations. I would like to hear if there are other approaches.

First I created a standard lens object. This allows me to create the aspheric surface with the circular clear aperture I desire. Edge radius is oversized at this point to allow for boolean addition later. Length is equal to the thickness of the microlens array substrate.

Next I created a rectangular volume to define the X and Y pitch of the individual element. This should fit inside the cylinder from step 1. Z length for the rectangular volume should be at greater than or equal to the length of the first object.

Then comes the Boolean Native with operation A&B to combine the two. This should leave you with a rectangular object, with a convex surface and circular aperture smaller than the square face. 

The final step is to use an Array object with the Boolean Native object as the Parent Object. Below I have the rectangular volume highlighted, shown inside the standard lens. Behind them is a 5x5 array of the boolean native object. 

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I hope that helps.

-Sean