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

The top five common freeforms have gained popularity with lens designers and optical system interrogators. 

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 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 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

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

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. 

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. 

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

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. 

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 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

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

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

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

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, detecting where the axis is and positioning it can be as complex as the
definition is simple. Make one or both of the surfaces aspheric and it gets even harder

The geometry of machines used to center lenses and to measure centering error all work in terms of the wedge case. Two important considerations are the centration of the lens and the difference in edge thickness. 

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. The results of testing done to qualify Optimax AR coatings for space ensure vacuum, temperature, and radiation stability

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

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. 

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 controlled

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

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 hot humid environments

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 takeaways for other manufacturers and designers

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

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

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?”

A basic survey of specifying aspheric forms, function and manufacturing and testing

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

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

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

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. 

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 Rochester Regional Photonics Cluster sought ways to promote itself and grow jobs in the Rochester region

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. 

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!”

A master’s degree in business administration offers personal and professional benefits to those whove earned them and their co-workers. – An RBJ interview including Mike Mandina and Rick Plympton

This Rochester Business Journal article speaks of Rick Plympton’s philosophy and career objectives to promote optics that benefit mankind – and have fun doing it

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. 

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 in the design process

Magnetorheological Finishing (MRF) offers an effective way for correcting transmitted wavefront of lenses. Optimax Systems uses this MRF process to correct aspheric lenses in transmission to subwavelength errors

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 of decenter or wedge, it all comes back to the difference in edge thickness. 

The primary design considerations are optical material, component size, shape and manufacturing tolerances. All of these attributes are variable at the design phase and have significant impact on lens manufacturing costs and therefore are outlined in a chart. 

Estimations for optical components are based on a set of reasonable assumptions. They are not meant to replace a complete analysis of the situation or design at hand, but rather to provide quick, easy-to-remember relationships for day-to-day use. 

Engineers from a variety of disciplines are now designing lens systems. Manufacturers are often asked to produce optics to tolerances that are not always optima, so practical manufacturing limits are important.    

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 assembly elements, so it is important to consider the management of it. 

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 specifications. 

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. 

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 to balance function and budget. 

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 optical surfaces. 

This Rochester Business Alliance article speaks of Mike Mandina’s innovative leadership and ‘in the trenches’ management style

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 in a case study

Founded in 1991, Optimax was one of the first optics manufacturers to use computer-controlled machining for the fabrication of optical components, reducing manufacturing time from 10 weeks to five days

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.

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 cost. 

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.