Year after year, program after program, Optimax continues to push the limits of possible in complexity, quality and speed for its customers.
Optimax excels at grinding, polishing and coating precision optics quickly and reliably. We can deliver high precision optics in as little as one week.
Customers trust Optimax to create high-quality optics and deliver them fast, and our freeforms are no exception. Designing with freeforms requires fewer elements, lighter weight and increased flexibility for your system.
Freeform optical shapes or optical surfaces are gaining popularity with lens designers and optical system integrators. Now, there are optical fabrication processes that include generation, high-speed VIBE polishing, sub-aperture figure correction, surface smoothing and testing of freeform surfaces.
Optimax is a leading producer in freeform optics from glass, fused silica, crystals and ceramics for UV, Visible and IR applications using proprietary techniques for low scatter surfaces.
Freeforms are optical shapes or optical surfaces that are designed with little to no symmetry. Manufacturing a freeform is similar to that of a highly complex asphere; surface form and local slope change are all factors that influence the complexity of the shape and the manufacturing process used.
To learn more about freeforms we invite you to visit Optimax’s Resources & Tools and read our Technical Papers on the topic.
Specifying a freeform begins by defining the surface. An optical fabricator needs a clear description of the desired final optic; equation, cloud of points or a 3D model.
Optimax utilizes deterministic CNC machine tools for predictable removal rates and adherence to tight tolerances. To control centration, precision tools maintain the optical axis.
Attribute |
Tolerancing Limit* |
| Diameter (mm) | +0, -0.010 |
| Center Thickness (mm) | ± 0.050 |
| Irregularity – Interferometry (HeNe fringes) |
0.1** |
| Irregularity – Profilometry (μm) | ±1.0 |
| Wedge Lens – ETD (mm) |
TBD |
| Surface Roughness (Å RMS) | 10 |
Based on Form Error Tolerance
Form Error > 2μm Lower Resolution Profilometry (2-D)1 |
||
|---|---|---|
Attribute |
Minimum |
Maximum |
| Diameter (mm) | 3 | 250 |
| Local Radius (mm) | -8 (Concave) | ∞ |
| Sag (mm) | 0 | 502 |
| Departure (mm) | 0.01 | 20 |
| Included Angle (°) | 0 | 120 |
Form Error 0.5 – 2μm Higher Resolution Profilometry (2-D)1 |
||
Attribute |
Minimum |
Maximum |
| Diameter (mm)3 | 3 | 250 |
| Local Radius (mm) | -12 (Concave) | ∞ |
| Sag (mm) | 0 | 252 |
| Departure (mm) | 0.01 | 20 |
| Included Angle (°) | 0 | 150 |
Form Error < 0.5μm Interferometry with Stitching (3-D) |
||
Attribute |
Minimum |
Maximum |
| Diameter (mm)3 | 3 | 250 |
| Local Radius (mm) | -13 (Concave) | ∞ |
| Sag (mm) | 0 | 252,4 |
| Departure (mm) | 0.002 | 1 |
| Included Angle (°) | 0 | 120+5 |
Attribute |
Minimum |
Maximum |
| Diameter | 3mm | 500mm |
| Wavelength | 193nm | 6000nm |
| Use Environment | Vacuum | >95% RH |
| Durability | Moderate abrasion | Severe abrasion |
| Measurement | — | 68°, s, p, average polarization |
| Laser Damage Threshold | — | 1064nm: >30J/cm2@10ns, >1MW/cm2CW |
| Layers | 1 | 200 |
Above are manufacturing limits and tolerances specific to thin film coating. For more detailed information, please contact sales@optimaxsi.com.
Rod or Arbor |
||
|---|---|---|
Attribute |
Minimum |
Maximum |
| Length (mm) | 3 | 5001 |
| Width (mm) Radius dependent | 2 | < 2x Radius |
| Cylinder Radius (mm) – Convex Only | 2 | 150 |
X-Y |
||
| Attribute | Minimum | Maximum |
| Length (mm) | 3 | 300 |
| Width (mm) | 2 | 300 |
| Cylinder Radius (mm) | 10 | ∞ |
| Concave sag to flat (mm) | 0.1002 | =Radius |
Attribute |
Minimum |
Maximum |
| Diameter (mm) | 3 | 300 |
| Thickness | 1 | 150 |
| Aspect Ratio1 | 1 | 502 |
Based on Form Error Tolerance
Attribute |
Minimum |
Maximum |
| Diameter (mm) | 3 | 400 |
| Radius (mm) | ±1 | ∞2 |
| Aspect Ratio (Diameter/Center Thickness) | <1:1 | 30:1 |
| Included Angle (°) | 0 | 2103 |
Here are manufacturing limits and tolerances specific to optical aspheres, prisms, cylinders and spheres. For more detailed information on any attribute, please contact sales@optimaxsi.com.
Optimax inspects 100% of all optics. Test data is provided with prototype orders.
Our metrology must match the sophistication of our manufacturing technology. Optimax offers state-of-the-art metrology, including surface profilers and interferometers to verify that parts meet the form error specification. Testing options are form specific, lenses with mild departure from a best-fit sphere have the highest potential for fractional wave precision.
Optimax manufactures a wide variety of optical components. When on-time delivery is crucial, Optimax offers an expedited delivery option with a money back guarantee.
Optimax’s R&D department is continuously looking for ways to improve our fabrication process and produce higher quality optics. Our current research projects are designed to meet future market needs.
For more information please see Optimax Innovation or contact sales@optimaxsi.com.
Freeform applications are expanding and include helmet-mounted displays, conformal optics, and those requiring the extreme precision of EUV. We will discuss the total manufacturing process and highlight the capabilities available today
We will present a case study of a characteristic freeform production optic that required an absolute positioning measurement procedure utilizing a custom dual computer generated hologram (CGH) interferogram set-up
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 of freeform surfaces for fabrication
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 traditional telescope assemblies. Three different monolithic telescope concepts, in different configurations and optical performance were produced as proof of concepts
With optical technology and design advances, larger freeform optics are increasingly sought after by consumers for an expanding number of applications. 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 work that will address each challenge
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.
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 understand optical performance.
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
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 of fused silica, glass, zinc-sulfide multispectral, and spinel.
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 the possibility for designers to manufacture these complex surfaces
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 the fabrication of non-rotationally symmetric lenses, such as freeform surfaces, economical
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 optical fabrication process
Freeform optical surfaces, which have little to no symmetry, are gaining popularity with lens designers and optical system integrators. Using fiducials properly leads to higher accuracy measurements and allows more control of the surface throughout the manufacturing process
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.
Optimax has placed emphasis on refining the deterministic form correction process. By developing many of these procedures in house, changes can be implemented quickly and efficiently in order to rapidly converge on an optimal manufacturing method
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