Free-form surfaces are quickly becoming a desired and necessary shape for many refractive and reflective optical
systems. Some examples of free-form shapes are toroids, ogives, and other conformal windows. In this paper, we will discuss the round-robin study of surface irregularity measurements of a free-form toroidal window

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

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

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

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

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 will impact the temperature, which we will explore in this paper

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 market. 

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 concentrations

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, due to the material hardness, polycrystalline nature, and non-traditional shape. Creative optical fabrication techniques, including VIBE™, help produce these types of optics cost-effectively

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 a high speed, cost effective process to produce such windows. 

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 reviewed and soak schedules are created. 

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 space to enable features like undercuts and internal channels. 

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. 

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. 

The importance of understanding the design and use of Fizeau transmission spheres, for accurate evaluation of surface
irregularities, cannot be understated. There are several characteristics that have a significant impact on the interpretation
of the resulting data. Specific tests can be performed on a routine basis to quantify and maintain calibration of the
precision masters and as a result, errors attributed to the transmission sphere can be isolated. The overall goal is to
obtain accurate evaluations of surface irregularities of the actual surface under test

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

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 controlled

Complete freeform optical fabrication process that includes ultrasonic generation of hard ceramic surfaces, high speed VIBE polishing, sub-aperture figure correction of polycrystalline materials, finishing and final testing of freeform surfaces

Optimax’s sapphire production process achieves significant improvement in cost by the implementation of a controlled grinding process to present the best possible surface to the polishing equipment

When cementing lenses together at Optimax, there are main options for assembly methods. Each method has its own benefits and challenges to be considered. 

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