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A recently reported vision ray metrology technique [Opt. Express29,43480(2021)OPEXFF1094-408710.1364/OE.443550] measures geometric wavefronts with high precision. This paper introduces a method to convert these wavefront data into height information, focusing on the impact of back surface flatness and telecentricity errors on measurement accuracy. Systematic errors from these factors significantly affect height measurements. Using ray trace simulations, we estimate reconstruction errors with various plano-concave and plano-convex elements. We also developed a calibration technique to mitigate telecentricity errors, achieving submicron accuracy in surface reconstruction. This study provides practical insights into vision ray metrology systems, highlighting validity limits, emphasizing the importance of calibration for larger samples, and establishing system alignment tolerances. The reported technique for the conversion of geometric wavefronts to surface topography employs a direct non-iterative ray-tracing-free method. It is ideally suited for reference-free metrology with application to freeform optics manufacturing. 

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. 

This feature issue of Optics Express highlights 28 state-of-the-art articles that capture a snapshot of the recent developments in the field of freeform optics. As an introduction, the editors provide an overview of all published articles, which cover a broad range of topics in freeform optics. The wide variety of applications presented here demonstrates that freeform optics is a growing and vibrant field with many more innovations to come. 

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. 

This work presents a stable noise-robust numerical integration technique derived from a gradient representation of the Q-Forbes polynomials for surfaces with axial symmetry. This modal-integration technique uses an orthogonalization process through the Householder reflections to obtain a numerically orthogonal set for the surface slopes that is used to reconstruct the surface shape. It is shown that for typical Deflectometry measurements, the resulting random component of the uncertainty after numerical integration has a root mean square error well below 1nm. 

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. 

A super-sensitive phase measuring Deflectometry technique is presented to obtain effective fringe periods beyond the MTF limit. This allows decreasing significantly the random component of the uncertainty in the measured slope.