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

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

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. 

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. 

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

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

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 I design it, can you really make it?”

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

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 difference. 

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. 

Three, four, and five-axis machining centers are used to grinding, polishing, and shaping the lenses with diamond tooling. Optimax now has five times more equipment and has added a third shift, increasing grinding and polishing productivity. 

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%

Learning the chemical aspects of optical polishing can lead to better optics in less time.

Tolerancing optical lenses in transmission rather than reflection offers financial, performance and delivery advantages to a given class of aspheric optics. 

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 surfaces are presented

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. 

A conventional study was conducted with infrared material zinc sulfide with the goal of producing defect-free polished surfaces in a predictable amount of time. 

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 frequency (MSF) errors in a VIBE finishing step.

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. 

The VIBE process is a full-aperture, conformal polishing process that uses high-frequency and random motion to rapidly remove sub-surface damage and eliminate mid-spatial-frequency surface errors.