In the last 10 years, freeform optics has enabled compact and high-performance imaging systems. This article begins with a brief history of freeform optics, focusing on imaging systems, including marketplace emergence. The development of this technology is motivated by the clear opportunity to enable science across a wide range of applications, spanning from extreme ultraviolet lithography to space optics. Next, we define freeform optics and discuss concurrent engineering that brings together design, fabrication, testing, and assembly into one process. We then lay out the foundations of the aberration theory for freeform optics and emerging design methodologies. We describe fabrication methods, emphasizing deterministic computer numerical control grinding, polishing, and diamond machining. Next, we consider mid-spatial frequency errors that inherently result from freeform fabrication techniques. We realize that metrologies of freeform optics are simultaneously sparse in their existence but diverse in their potential. Thus, we focus on metrology techniques demonstrated for the measurement of freeform optics. We conclude this review with an outlook on the future of freeform optics.
- PAR ID:
- 10518280
- Editor(s):
- Aikens, David M; Rehn, Henning; Thibault, Simon; Uhlendorf, Kristina
- Publisher / Repository:
- SPIE
- Date Published:
- Journal Name:
- SPIE
- ISBN:
- 9781510668508
- Page Range / eLocation ID:
- 82
- Format(s):
- Medium: X
- Location:
- Quebec City, Canada
- Sponsoring Org:
- National Science Foundation
More Like this
-
more » « less
-
more » « less
A freeform pushbroom hyperspectral imager design was investigated as a combination of a freeform reflective triplet imager and a freeform reflective triplet spectrometer used in double-pass. The design operates at about F/2 with a 15-degree cross-track field-of-view and a 30 mm entrance pupil diameter. The design process led to achieving a small volume of less than 2 liters that fits comfortably within a 3U CubeSat geometry, exemplifying the compactness of this hyperspectral imager. We report the freeform sag departures and maximum slopes of the freeform surfaces, as well as the manufacturing tolerances together with an evaluation of the system stray light, all of which highlight the feasibility of a design in this class to be manufactured. This design uniquely positions itself on the landscape of compact hyperspectral imagers.
-
more » « less
Freeform optical components enable dramatic advances for optical systems in both performance and packaging. Surface form metrology of manufactured freeform optics remains a challenge and an active area of research. Towards addressing this challenge, we previously reported on a novel architecture, cascade optical coherence tomography (C-OCT), which was validated for its ability of high-precision sag measurement at a given point. Here, we demonstrate freeform surface measurements, enabled by the development of a custom optical-relay-based scanning mechanism and a unique high-speed rotation mechanism. Experimental results on a flat mirror demonstrate an RMS flatness of 14 nm (∼λ/44 at the He-Ne wavelength). Measurement on a freeform mirror is achieved with an RMS residual of 69 nm (∼λ/9). The system-level investigations and validation provide the groundwork for advancing C-OCT as a viable freeform metrology technique.
-
more » « less
Freeform Fresnel optics represent an emerging category of modern optics that reproduces powerful optical functionalities while maintaining an ultra-compact volume. The existing ultra-precision machining (UPM) technique faces technical challenges in meeting the fabrication requirements for freeform Fresnel optics because of the absence of appropriate geometry definition and corresponding tool path planning strategy to overcome the extreme asymmetry and discontinuity. This study proposes a new scheme for ultra-precision machining using four axes (
X ,Y ,Z ,C ) to fabricate freeform Fresnel optics, including a general geometry description for freeform Fresnel optics, the quasi-spiral tool path generation strategy to overcome the lack of rotary symmetry, and the adaptive tool pose manipulation method for avoiding tool interference. In addition, the tool edge compensation and the adaptive timestep determination are also introduced to enhance the performance and efficiency of the proposed scheme. The machining of two exemplary freeform Fresnel lenses is successfully demonstrated. Overall, this study introduces a comprehensive routine for the fabrication of freeform Fresnel optics and proposes the adaptive tool pose manipulation scheme, which has the potential for broader applications in the ultra-precision machining of complex or discontinuous surfaces.
