Optimax Technical Papers

Freeform Technical Expertise

Freeform Expertise Technical Papers

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.

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

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 smoothing results of a highly skilled artisan

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.

Fabrication of Freeform Optics

Freeform surfaces on optical components have become an important design tool for optical designers. Non-rotationally symmetric optical surfaces have made solving complex optical problems easier. The manufacturing and testing of these surfaces has been the technical hurdle in freeform optic’s wide-spread use.

Round-robin measurements of the toroidal window

Freeform surfaces are quickly becoming a desired and necessary shape for many refractive and reflective optical systems. In this paper, we will discuss the round-robin study of surface irregularity measurements of a freeform toroidal window.

Fabrication and metrology of high-precision freeform surfaces

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.

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 both the irregularity and the location of the freeform surface simultaneously.

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 of freeform surfaces for fabrication.

The Manufacturing of a Multi-surface Monolithic Telescope with Freeform Surfaces

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.

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.

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 work that will address each challenge.

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 mm.

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.

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.

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 understand optical performance. 

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.

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 of fused silica, glass, zinc-sulfide multispectral, and spinel. 

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 the possibility for designers to manufacture these complex surfaces.

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.

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.

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 the fabrication of non-rotationally symmetric lenses, such as freeform surfaces, economical.

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 optical fabrication process.

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.

Importance of Fiducials on Freeform Optics

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.

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. 

Metrology of Freeform Optics

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

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.

Deterministic Form Correction of Extreme Freeform Optical Surfaces

Optimax has developed a variety of new deterministic freeform manufacturing processes by combining traditional optical fabrication techniques with cutting edge technological innovations.

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.