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Point spread function engineering uses specially designed phase plates placed at the exit pupil of an imaging system to reduce defocusing sensitivity. A custom phase plate is typically required for each system to enable extended depth of field imaging, so methods enabling variable extended depth of field imaging are of particular interest. In this paper, we discuss the fabrication of previously designed fixed cubic phase plates and variable phase plate pairs with quartic surface profiles and present a novel application of a point source microscope for performance characterization. Experimental measurements of through-focus point spread functions are compared with predictions to demonstrate and characterize the extended depth of field for both fixed and variable freeform phase plates. 

Dynamic illumination using tunable freeform arrays can enable spatial light distributions of variable size with high uniformity from non-uniform sources through relatively small opposing lateral shifts applied to the freeform components. We present the design, manufacturing, and characterization of a tunable LED-based illuminator using custom freeform Alvarez arrays with commercially available optics to shorten the manufacturing cycle. The optomechanical design and manufacturing of the Alvarez lens arrays and mounting parts are presented in detail. The optical performance of the system is evaluated and compared with simulation results using a custom camera-based test station. Experimental results demonstrate and confirm the dynamic illumination concept with good uniformity. 

A novel Vision ray metrology technique is reported that estimates the geometric wavefront of a measurement sample using the sample-induced deflection in the vision rays. Vision ray techniques are known in the vision community to provide image formation models even when conventional camera calibration techniques fail. This work extends the use of vision rays to the area of optical metrology. In contrast to phase measuring deflectometry, this work relies on differential measurements, and hence, the absolute position and orientation between target and camera do not need to be known. This optical configuration significantly reduces the complexity of the reconstruction algorithms. The proposed vision ray metrology system does not require mathematical optimization algorithms for calibration and reconstruction – the vision rays are obtained using a simple 3D fitting of a line. 

Vision ray techniques are known in the optical community to provide low-uncertainty image formation models. In this work, we extend this approach and propose a vision ray metrology system that estimates the geometric wavefront of a measurement sample using the sample-induced deflection in the vision rays. We show the feasibility of this approach using simulations and measurements of spherical and freeform optics. In contrast to the competitive technique deflectometry, this approach relies on differential measurements and, hence, requires no elaborated calibration procedure that uses sophisticated optimization algorithms to estimate geometric constraints. Applications of this work are the metrology and alignment of freeform optics. 

Precision glass molding is a viable process for the cost-effective volume production of freeform optics. Process development is complex, requiring iterative trials of mold manufacture and metrology, glass mold prototyping, metrology and functional testing. This paper describes the first iteration in the development of a process for an Alvarez lens for visible light. The challenges of this optic are extremely tight band-RMS tolerances on a freeform shape over a maximum clear aperture of 45 mm, a 16:1 aspect ratio and a freeform departure of 329 micrometers. A freeform glass mold for an Alvarez lens was manufactured by coordinated-axis diamond turning in a mold substrate using a custom tool error correction method. The results of prototype precision glass molding are also reported. Mold surfaces and molded optical surfaces are analyzed with scanning white light interferometry. A surface roughness of approximately 3 nm RMS is obtained for both the mold substrate and the glass optic with high-fidelity reproduction of micro-surface structure in the glass. These measurements also identify challenging areas, particularly the presence of mid-spatial frequency errors on the optic originating from the machine thermal control system. The form of the molds was also measured with a profilometer; however, the mold surface does not agree with the expected prescription with an overall deviation in form of approximately 10 μm. The machining process is expected to have sub-micrometer error and the sources of this discrepancy are still being determined. Metrology of the glass optics is currently in progress.