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We developed, tested, and applied a software tool that automatically generates high-accuracy CAD models of freeform elements with datums and fiducials, facilitating the efficient transition from freeform design to fabrication and measurement. 

Afocal telescopes are often used as foreoptics to existing imaging systems. Here, we discuss some unique aspects of designing afocal systems and detail various afocal design studies we performed using freeform optics. 

Nodal Aberration Theory (NAT) was developed to explain the field dependency of aberration field centers in the image plane of nominally rotationally symmetric optical systems that have lost their symmetry through misalignments. A new insight into the theory led to calculating the sigma vectors, which locate the aberration field centers, using the angle between a real-ray trace of the optical axis ray (OAR) and the normal of the local surface where “local” refers to the object and image optical spaces of that surface. Here, we detail the sigma vector calculations for general optical systems and provide an experimental investigation of a misaligned system with a high-precision customized Cassegrain telescope. In the simulations, a Newtonian telescope, a Cassegrain telescope, and a three-mirror anastigmat telescope were misaligned intentionally in ray-tracing software. The sigma vectors were calculated analytically for the third-order aberrations of astigmatism and coma. Experimentally, the same perturbations were implemented for the Cassegrain telescope system, and the aberrations were quantified through interferometric measurements on a grid of field points in the image plane that verified the analytical derivation and simulations. 

Traditional optical manufacturing techniques such as abrasive polishing and diamond turning create precise surfaces by removing material from the optical surface of a mirror. Such techniques often require many cycles of removal and metrology and can leave surface roughness or tool marks that negatively affect the straylight properties of an optical system. These residual artifacts often necessitate expensive postprocessing such as ion beam finishing. Limiting straylight is particularly crucial in the design of reflecting coronagraphs or optical systems that are sensitive to scattered light, for example for exoplanet detection, where even low-level scattering can degrade contrast ratios below the sensitivity needed to detect exoplanets. We introduce a non-contact method for shaping thin front-surface mirrors to avoid tool artifacts. Using laser techniques to alter local surface stresses, we deterministically introduce ≥ 8 waves (632.8 nm) of shape to 2 mm thick substrates. A deterministic method for creating arbitrary surface figures is under development and calibration. 

In this work, we present a methodology for predicting the optical performance impacts of random and structured MSF surface errors using pupil-difference probability distribution (PDPD) moments. In addition, we show that, for random mid-spatial frequency (MSF) surface errors, performance estimates from the PDPD moments converge to performance estimates that assume random statistics. Finally, we apply these methods to several MSF surface errors with different distributions and compare estimated optical performance values to predictions based on earlier methods assuming random error distributions.

 

Tolerancing is a critical step in creating successful commercial products. We explore recent advances in tolerancing illumination optics with particular emphasis on surface perturbations and extended sources. 

We consider the requirements for first-order pupil location control using the matrix method for both finite-conjugate systems and afocal systems at infinite imaging conjugates. We show that two-element systems allow for only limited pupil location control, while with three elements or more the first-order pupil locations can be freely and independently controlled. 

Afocal telescopes are often used as foreoptics to existing imaging systems to allow for application flexibility. To properly combine an afocal telescope with an existing imaging system, the exit pupil of the afocal telescope and the entrance pupil of the imaging system must be coincident. Additionally, the exit pupil of the afocal telescope must be well-formed; that is, it must be the correct size and shape to mitigate pupil-matching challenges. This work introduces processes for designing freeform afocal telescopes with an emphasis on understanding how to analyze and control the exit pupil quality of such systems. The included 3-mirror design examples demonstrate the advantages of using freeform surfaces in afocal systems and quantify the tradeoffs required to improve the exit pupil quality.

 

We apply the Nb=1 solution of the Rapidly Decaying Fourier series to fit mid-spatial frequency surface errors. Using this basis enables definition of sharp spatial frequency bandlimits for mid-spatial frequency specification of optical surfaces. 

We describe the development of a data library of mid-spatial frequency surface errors for optical components. This resource enables better understanding of specification of mid-spatial frequency surface errors and their connections to optical performance.