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We are a world leader in high precision optical manufacturing, delivering custom optics to a wide range of innovators around the globe. Meeting these goals demands the right people. Teamwork, adaptability, and an enthusiastic approach to problem-solving are central to the Optimax culture. But what unites all our employees best is a hunger to continuously learn. We strive to find driven individuals who are committed to lifelong learning; who will continue to add value in their work throughout long and successful careers.

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Freeform Lens

Optical designers and integrators choose Optimax freeforms because our quality and reliability are second-to-none. We offer high-precision freeform optical shapes which have small footprints and lighter profiles, enabling reduced system complexity.

With an expansive team of technical experts, Optimax is one of the largest leading producers of freeform optics, combining optimal grinding and smoothing technologies to fabricate precise components with positional and mid-spatial frequency errors.

This allows us to take on the most challenging projects and we can generate high precision freeforms for UV, Visible and IR applications using proprietary techniques for low scatter surfaces.

Freeforms

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What are Freeform Optics?

Freeform optics have been gaining popularity with lens designers for years. They empower optical designers to create more compact systems which weigh less than traditional optics while enabling them with greater flexibility. Freeform optical shapes are a doorway into a world of innovation, and Optimax is primed to help designers to take advantage of their unique capabilities.

Freeforms

FLATS / PLANOS

No curvature
Radial symmetry

Freeforms

SPHERES

Constant radius
Radial symmetry

Freeforms

ASPHERES

Varying radius
Radial symmetry

Freeforms

FREEFORMS

Non-constant curvature
Little to no symmetry

Freeforms
Freeforms

Types of Freeforms

We have leveraged our advanced manufacturing technology to develop a variety of different types of freeform optical shapes and lenses, including.

  • Toroid
  • Atoroid/Biconic
  • Acylinder
  • Off-Axis Parabola (OAP)
  • Anamorph
  • XYZ Freeforms or Solid Model
  • Other Equation-Based Freeforms
The most common types of freeforms now are mild, wild and extreme.
The difference between these three is size, shape and measurability.

MILD

  • Interferometric test available
  • Applicable to most surfaces
  • Can measure freeform surfaces to fractional wave PV

WILD

  • Interferometric test not available
  • Typically measured using single point probe measurements
  • Applicable to most surfaces
  • Good for form errors to 1 um PV

EXTREME

  • Interferometric test not available
  • Typically measured using single point probe measurements
  • Applicable to most surfaces
  • Good for form errors to 1 um PV

Specifying Freeform Optics

Freeform optical shapes or surfaces are designed with little to no symmetry. As with highly complex aspheres, freeform optical design is influenced by local slope change and surface form, particularly when it comes to the complexity of the shape and the manufacturing process used. Freeform optical shapes are typically more complex than aspheres, and are considered by many to be the next generation for optical systems. The experienced team of optical fabricators at Optimax can work with equations, cloud of points, and/or robust 3D models. Although the demands of freeform optical manufacturing are extremely complicated, we have years of experience and accumulated technical know-how at our disposal. We are uniquely capable of rapidly delivering as specified freeforms with complex geometries in small, lightweight formats.

Freeforms

Manufacturing Freeform Optics

Our precision engineering and measurement capabilities allow us to tolerance strict limits for freeform surfaces, enabling the generation of mild, wild, and extreme surfaces. At Optimax, we work to ensure our collaborations are innovatively driven, meaning we are continuously looking for new ways to measure, specify, and tolerance freeform surfaces.

Learn more about the careful consideration given to manufacturing tolerances, the iterative process of deriving those tolerances, and general freeform manufacturing limits.

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Technical Expertise

Do you want to learn more about freeform optics? Refer to our Knowledge Centre to read technical papers on the fabrication of freeform optics, the challenges inherent in scaling-up freeform optical design, and how Optimax can help you overcome those challenges.

Freeform Optics

Towards understanding tool influence function (TIF) spots during hemispherical sub-aperture tool polishing

Freeform optics are typically fabricated using sub-aperture tool grinding and polishing. This polishing method requires a detailed understanding of the local material removal (tool influence function or TIF) at the …

Freeform Optics

Force responsive robotic controlled figuring and smoothing of lightweight freeform mirrors

Optical fabrication of freeform lightweight mirrors often results in mid-spatial frequency (MSF) and/or surface quilting surface errors.

Freeform Optics

Freeform Monolithic Multi-Surface Telescope Manufacturing

The freeform monolithic multi-surface telescope design has all its off-axis optical surfaces manufactured from a single optical blank, resulting in truly monolithic telescope design, providing improvements in stability and payload.

Freeform Optics

If you can't measure it, you can’t make it: the importance of metrology in optics fabrication Optimax’s 30 year history

This paper briefly tells the story of the importance of metrology in optics fabrication at Optimax, and highlights Wyko and Jim Wyant’s contribution to early Optimax success.

Freeform Optics

Smoothing Mid-spatial Frequency (MSF) Errors on Freeform Optics with an Algorithm-based Robotic Platform Utilizing Deflectometry Input

Optimax has developed the HERMES (High-End Robotic MSF Elimination System) a robotic platform that uses a machine learning algorithm to smooth parts. Results indicate that HERMES fared well compared to …

Freeform Optics

Fabrication of a 500 mm Extreme Freeform Conformal Window

There is a potential need for large (>500 mm diameter) conformal windows for use on air, space, and watercraft.

Freeform Optics

Absolute freeform surface measurement using interferometry

This case study will focus on the absolute freeform surface measurement utilizing a custom dual CGH and interferometer set-up, with special emphasis on reference artifacts and surface alignment to measure …

Innovative Optics Manufacturing

Design and Manufacturing Considerations for Freeform Optical Surfaces

Freeform optical systems are becoming increasingly common due to new design and manufacturing methods. We present an example compact freeform optical system and describe considerations for transfer of the prescription …

Innovative Optics Manufacturing

Scaling-up freeform manufacturing: challenges and solutions

This paper will present some of the challenges and solutions of extending freeform polishing capabilities from approximately 150 mm diameter parts to a component of over 500 mm in diameter.

Freeform Optics

Larger format freeform fabrication and metrology

This paper will address challenges that have been encountered in the manufacturing, testing, and handling of freeforms as their size expands up to and beyond 500 mm, and provide future …

Innovative Optics Manufacturing

Challenges in size scale up of freeform polishing processes

This paper will discuss challenges faced as a result of scaling up our freeform polishing process from parts with approximately 150 mm diameters, to polishing components with diameters over 600 …

Freeform Optics

Pushing Freeform Optical Manufacturing: Fabricating Optimax’s Largest Freeform Component

Several challenges associated with part size and shape complexity were solved during the manufacture of the largest extreme freeform shape Optimax has fabricated to date.

Freeform Optics

Measurement of mid-spatial frequency errors on freeform optics using deflectometry

Freeform optics have emerged as a new tool for optical designers and integrators. Manufacturing innovations are gradually increasing availability of precision freeform optics.

Freeform Optics

Integrating Optical, Mechanical and Test Software

Optical systems must perform under environmental conditions including thermal and mechanical loading. To predict the performance in the field, an integrated analysis combining optical and mechanical software is required to …

Freeform Optics

Advances in Freeform Optics Fabrication for Conformal Window and Dome Applications

Freeform optical shapes or optical surfaces that are designed with non-symmetric features are gaining popularity. This enabling technology allows for conformal sensor windows and domes that provide enhanced aerodynamic properties.

Freeform Optics

Conformal window manufacturing process development and demonstrations for polycrystalline materials

Conformal windows pose new and unique challenges to manufacturing due to the shape, measurement of, and requested hard polycrystalline materials. Optimax has developed a process for manufacturing conformal windows out …

Freeform Optics

Metrology for the Manufacturing of Freeform Optics

Freeform optical surfaces are gaining popularity with lens designers and optical system integrators as a method to solve complex optical system design problems. Fortunately, advances in optical manufacturing have opened …

Freeform Optics

Freeform Optical manufacturing and testing processes for IR Conformal Window and Domes

Freeform optical shapes that are designed with non-symmetric features allow for conformal sensor windows and domes that provide enhanced aerodynamic properties as well as environmental and ballistic protection.

Freeform Optics

Manufacturing and Metrology for IR Conformal Windows and Domes

Freeform and conformal optics have the potential to dramatically improve optical systems by enabling systems with fewer optical components, reduced aberrations, and improved aerodynamic performance.

Freeform Optics

Fabricating freeform multispectral-ZnS corrector lenses

For more than 100 years, optical imaging systems were limited to rotationally symmetric lens elements, due to limitations in processing optics. However, the present application of CNC machines has made …

Freeform Optics

Tolerancing an Optical Freeform Surface

Freeform optical shapes or optical surfaces that are designed with non-symmetric features are gaining popularity with lens designers and optical system integrators. Tolerances on a freeform optical design influence the …

Freeform Optics

The need for Fiducials on Freeform Optical Surfaces

Freeform surfaces typically have little to no symmetry, making the alignment of the surfaces difficult. Fiducials are required to achieve higher accuracy measurements of freeform optical surfaces.

Freeform Optics

Manufacturing of a large, extreme freeform, conformal window with robotic polishing

Our robotic polishing platforms are able to polish large, difficult-to-make optical surfaces with minimal surface error. 

Freeform Optics

Metrology of Freeform Optics

Proper metrology is required to monitor and verify the freeform fabrication processes to improve capability and precision.

Freeform Optics

Fabrication of Freeforms

Optimax has developed a robust freeform optical fabrication CNC process that includes generation, high speed VIBE polishing, sub-aperture figure correction, surface smoothing and testing of freeform surfaces.

Freeform Optics

Producing Smooth Surfaces on Polycrystalline ZnS Aspheres and Freeforms

The addition of VIBE smoothing as the final optical fabrication process yields highly smooth surfaces on polycrystalline aspheres, improving optical performance. 

Freeform Optics

Fabricating and Testing Freeform Optics

Freeform optical shapes or optical surfaces that are designed with non-symmetric features are gaining popularity with lens designers and optical system integrators. A common question about freeform optics is, “If …

Innovative Optics Manufacturing

Design and Manufacturing Considerations for Freeform Optical Surfaces

Freeform optical systems are becoming increasingly common due to new design and manufacturing methods. We present an example compact freeform optical system and describe considerations for transfer of the prescription …

Manufacturing the Future

At Optimax, we are manufacturing the future, creating the highest precision freeform optics underlying high-tech systems in key markets and applications. We offer rapid and expedited delivery upon request and are committed to our customers in the long term.

Submit an RFQ to start building your relationship with one of the world’s foremost manufacturers of freeform optical shapes.

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Optimax develops optics solutions to suit a variety of needs. Our industry-leading custom optics are developed by expert engineers. Discover our expertise, solutions, and opportunities today.

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