In addition to tradeoffs between mirror reflectivity, wavefront, laser-damage threshold, and cost, new low-stress coatings offer weight, geometry, and thermomechanical performance and design flexibility.  

Lens design software analyzes optical tolerances by modeling a perturbed optical system to capture the effect of simultaneous changes in manufacturing and alignment errors.

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 …

The use of high-power continuous wave (CW) lasers in the emerging directed energy (DE) market has put greater emphasis on the quality of optical coatings.

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

One third of the exchanged final turning mirrors on the National Ignition Facility have been laser damaged by 3ω (351nm) target backscattered light. The mirrors are spectrally complex hafnia and …

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.

Learn how increasing oxygen partial pressure during deposition improves film stoichiometry, absorption, and laser-induced damage threshold (LIDT) at 351 nm.

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.

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 …

There are many topics to consider during aspheric lens design, including geometrical restrictions that hinder producing particular aspheric shapes. Understanding these restrictions will help drive costs. 

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

Optimax uses a variety of 3D printers to streamline our manufacturing processes. Download our technical paper today to learn about our results. 

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 …

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 …

Monolithic multi-surface telescopes combined with freeform optical surfaces provide improvements in optical performance in a smaller footprint as compared to systems with spherical surfaces, while providing superior mechanical stability to …

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.

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 …

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 …

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

As U.S. manufacturing works to overcome a technical skills gap, apprenticeships are gaining favor as a post-secondary educational path.

Completing our suite of deposition equipment, we are developing a new Ion Beam Sputtering (IBS) System with different substrate configurations.

Opticians have for years kept polishing pitch in electrified containers called “pitch pots” that keeps it in at an elevated temperature. By insulating the top of a pitch pot, it …

The Optics and Electro-Optics Standards Council (OEOSC) Task Force (TF) 7 has proposed a Type 1 laser damage test procedure and deemed it the most valuable in the U.S. laser …

This work presents an overview of the Segmented Aperture Interferometric Nulling Testbed (SAINT), a project that will pair an actively-controlled macro-scale segmented mirror with the Visible Nulling Coronagraph (VNC). 

This explores quick predictive methods for calculating potentially risky stresses in cemented doublets underdoing temperature change that agrees well with finite element analysis. It also provides guidelines for avoiding stress …

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 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.

Optical designers assume a mathematically derived statistical distribution of the relevant design parameters. Presented are measured distributions using lens manufacturing data to better inform the decision-making process.

Optical designers assume a mathematically derived statistical distribution of the relevant design parameters. However, there may be significant differences between the assumed distributions and the likely outcomes from manufacturing. 

Hard ceramic conformal windows and domes provide challenges to the optical fabricator. Creative optical fabrication techniques, including VIBE™, help produce these types of optics cost-effectively.

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 …

Sapphire poses very difficult challenges to optical manufacturers due to its high hardness and anisotropic properties. These challenges can result in long lead times and high prices. Optimax is developing …

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

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 …

When manufacturing precision optical surfaces of relatively larger sizes it is critical to understand the thermal stability of the substrate material. The material properties associated with thermal homogenization are commonly …

Optimax has developed a fabrication process that not only reduces cost but also aids in producing spherical sapphire components to better figure quality. 

Additive manufacturing, or 3D printing, has become widely used in recent years for the creation of both prototype and end-use parts. The flexibility is unparalleled and has opened the design …

The VIBE™ process is a full-aperture, conformal polishing process that has the potential to be introduced in areas of today's modern optics manufacturing process.

Improvements to sensing hardware and image processing for airborne optical systems have inspired designers to propose new optics and windows to be: more precise, conformal/freeform and multi-functional. 

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 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.

With so many types of optical components, there are many considerations early in the manufacturing process that can save resources.

Optimax developed a new magnetorheological (MR) fluid for studying the relative contributions of mechanics and chemistry in polishing hard materials. 

In an effort to reduce variation and improve predictability, Optimax integrated magnetorheological finishing into its aspheric lens manufacturing process.

Many changes have occurred in business strategies for precision optics manufacturing. The internalization of the photonics industry and the value derived from Rochester's regional photonics cluster are important insights. 

The optical axis of a spherical lens is the axis passing through the two centers of curvature of the optical surfaces. It is such a simple thing to describe. However, …

Optimax Systems uses this MRF process to correct aspheric lenses in transmission to subwavelength errors.

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

Space can be a harsh environment for optical coatings. Optimax has successfully provided antireflection (AR) coatings for a wide range of space applications.

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

Every optical application requires a “clean” optical surface. However, what defines “clean” is subjective and is based on the needs of the application.  

There are many decisions to make when designing, specifying, manufacturing, and testing optical components for high-energy laser systems — each is a potential failure mechanism that must be understood and …

Optimax has developed a novel optical coating (OTR‐AR). OTR coatings have been demonstrated to provide excellent resistance to latent scratching, staining and dimming of chemically sensitive optical glass surfaces in …

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.

Design, specification, and procurement of optical coatings all benefit when the designer has a good understanding of measurement techniques and uncertainties.

The cost of lenses is strongly dependent on the difference between the specified tolerances and the limits of the optics manufacturer, the coater, and the metrologist. 

Cylinder manufacturing methods can influence specification, offering recommendations on what to consider when designing cylindrical optical components to minimize cost and allow for greater flexibility in manufacturing. 

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

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 …

Total cost of a part is calculated over its entire lifespan. By investing in higher quality and reliability, total cost decreases as supporting costs become less necessary. 

This paper, written by Optimax, tells the story of how Optimax was founded and how we are able to support “Prototype Optics in 1 Week!”.

CLEARCERAM® was developed in an attempt to reduce the thermal expansion and approach a true zero expansion material. This improves grinding and polishing rates by 39%.

This paper is an introduction to the specification and tolerancing of Mid-spatial frequency (MSF) ripple or waviness.

The concept for polishing optical elements with a process called VIBE is presented, application to non uniformly sloped optics such as aspheric shapes is detailed, and initial results on spherical …

OptiDomes act as a standard for metrology testing of various testing methods for measuring the surface quality, mechanical attributes and/or the transmitted wave-front error of hemispherical/spherical domes.

Aluminum oxynitride (ALON™) spans from the UV to the IR and has excellent ballistic characteristics and is used to improve quality in manufacturing. 

With increasing demand for deep UV applications, special considerations must be taken to produce the optics. Specifically, as the wavelength of incident light decreases, the importance of smooth surfaces increases. 

The similarities and differences between tolerancing, manufacturing, and measuring spherical and aspheric surfaces are important.

There are parameters used in specifying centration of a lense and techniques used to check the location of and position the optical axis. Whether centering errors are specified in terms …

Prisms are optical components used to reflect or refract light. Their distinct characteristics give rise to its own language, the language of prisms. 

One design strategy for an optical system is centering two or more lenses together to build a lens assembly. However, strain in excess may cause delamination or fracture of the …

Selecting the material from which a lens is made is a fundamental design consideration. In certain situations, a substitute or equivalent material may need to be identified depending on the …

This paper will define surface irregularity for spherical surfaces, offer information on measurement methods for testing surface irregularities, and some specification guidelines.

There are two main paths for tolerancing spherical radii: power tolerance and linear radius tolerance. Both measure change relative to a nominal value, but the metrology used is the key …

Mechanical attribute tolerances can be a major cost driver because of time and yield penalties added to fabrication of a lens. Dimensions and their tolerances are interrelated, so designers need …

Centration errors arise from deviation from superposition. In a perfectly centered lens, the mechanical and optical axes are concurrent and coincidental, superimposed on each other.  

Mid-spacial frequency wavefront error, slope, and PVr have a big effect on optical component manufacturing. Specifying them can help reduce error. 

Phase-shifting interferometry is widely used to determine form errors of an optical surface in optical manufacturing. These distortions can affect the ability to get accurate data on thin film coated …

As a result of placing in the top 20 of Inc. Magazine's and Winning Workplaces 2010 Top Small Company Workplaces Competition, Optimax was contacted by the Hitachi Foundation to participate …

The VIBE™ process is a full aperture, conformal polishing process incorporating high frequency and random motion designed to rapidly remove sub-surface damage in a VIBE pre-polish step and eliminate mid-spatial …

Historically, the R&D department and the optical manufacturing shop floor have been independent entities. Optimax has been able to integrate the two departments for faster deployment and practical utilization. 

There are many topics to consider during aspheric lens design, including geometrical restrictions that hinder producing particular aspheric shapes. Understanding these restrictions will help drive costs. 

The evolution of the manufacturing technology for a specific aspheric glass lens can provide significant image quality improvement, reduction of the number of lens elements, smaller size, and lower weight. 

There are numerous metrology options for aspheres, including how they work, requirements, and what is specified with each method in an effort to tolerance aspheres.

This paper will first detail where slope error originated from, what it represents and the role it plays in the optical performance.

This paper examines the role surface roughness plays in optical system performance, discusses the components of a surface roughness specification, and contrasts roughness with cosmetic defects.

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 …

In an effort to reduce variation and improve predictability, Optimax integrated magnetorheological finishing into its aspheric lens manufacturing process.

Testing and correcting the aspheric lens as it is used in transmission addresses some of the shortcomings of traditional 3D surface metrology.

Optimax improved the reliability of asphere polishing platforms at a demonstrated level. Download our technical paper today to learn about our results.

Optimax Systems, Inc., a leader in quick delivery prototype optics, has been manufacturing aspheric lenses for more than 20 years. Along the way, we have learned many lessons and provide …

Recent design methods and software advances make it much easier to design aspheric surfaces that actually work in production and test by considering manufacturability issues at the earliest possible stage …