Challenges and best practices for manufacturing freeform optics

Franciscus Wolfs; Scott DeFisher; James Ross; Kyle Wood

doi:10.1117/12.2601244

28 October 2021 Challenges and best practices for manufacturing freeform optics

Franciscus Wolfs, Scott DeFisher, James Ross, Kyle Wood

Proceedings Volume 11889, Optifab 2021; 118890Q (2021) https://doi.org/10.1117/12.2601244
Event: SPIE Optifab, 2021, Rochester, New York, United States

Abstract

Freeform optics are becoming more widely used in the optics industry to expand the capabilities of systems while reducing the package size and number of elements required in the system. The complexity of freeform designs introduces new challenges to the manufacturing flow compared to rotationally symmetric optics. New manufacturing techniques have been developed to solve these new challenges. In addition, as tolerances tighten on freeform surfaces, the methods used to address these challenges can be the difference between the part being inside or outside of tolerance. Successful manufacturing starts when designing the freeform part and choosing the proper datum structure. When moving to processing, choosing the right fixture is a key component of efficient manufacturing. Part measurements are critical to both perform error map driven figure corrections and to determine if the part is within tolerance. An easily oriented error map is a simple way to improve the surface while avoiding inducing new mid-spatial signatures into the part surface. This paper will present common challenges of manufacturing freeform optics and the best practices in designing, manufacturing, and measuring that will ensure the greatest chance of making a freeform optic that meets its specifications.

Conference Presentation

Citation Download Citation

Franciscus Wolfs, Scott DeFisher, James Ross, and Kyle Wood "Challenges and best practices for manufacturing freeform optics", Proc. SPIE 11889, Optifab 2021, 118890Q (28 October 2021); https://doi.org/10.1117/12.2601244

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