Technical Papers | Optical Manufacturing

Defining and Tolerancing Freeform Surfaces for ManufacturingFreeform optics presents unique challenges to designers and manufacturers. Understanding a vendor’s manufacturing and metrology capabilities is critical...Read More

Force controlled mid-spatial frequency error smoothing using machine learningFreeform optics have shown the ability to drastically increase optical design options, providing new solutions for space telescope and optics applications.READ MORE

Towards understanding tool influence function (TIF) spots during hemispherical sub-aperture tool polishingFreeform optics are typically fabricated using sub-aperture tool grinding and polishing. This polishing method requires a detailed understanding of the...Read More

Force responsive robotic controlled figuring and smoothing of lightweight freeform mirrorsOptical fabrication of freeform lightweight mirrors often results in mid-spatial frequency (MSF) and/or surface quilting surface errors.Read More

Freeform Monolithic Multi-Surface Telescope ManufacturingThe freeform monolithic multi-surface telescope design has all its off-axis optical surfaces manufactured from a single optical blank, resulting in truly...Read More

If you can’t measure it, you can’t make it: the importance of metrology in optics fabrication Optimax’s 30-year historyThis paper briefly tells the story of the importance of metrology in optics fabrication at Optimax, and highlights Wyko and Jim Wyant’s contribution to...Read More

Smoothing Mid-spatial Frequency (MSF) Errors on Freeform Optics with an Algorithm-based Robotic Platform Utilizing Deflectometry InputOptimax has developed the HERMES (High-End Robotic MSF Elimination System) a robotic platform that uses a machine learning algorithm to smooth parts....Read More

Fabrication of a 500 mm Extreme Freeform Conformal WindowThere is a potential need for large (>500 mm diameter) conformal windows for use on air, space, and watercraft.Read More

Design and Manufacturing Considerations for Freeform Optical SurfacesFreeform optical systems are becoming increasingly common due to new design and manufacturing methods. We present an example compact freeform optical system...Read More

Pushing Freeform Optical Manufacturing: Fabricating Optimax’s Largest Freeform ComponentSeveral challenges associated with part size and shape complexity were solved during the manufacture of the largest extreme freeform shape Optimax has...Read More

Advancements in Thin-film Coating MetrologyTightening specifications and increasing demands for high-performance optical coatings continue to drive advancements in many areas of the optical...Read More

Rapid Prototyping of Ultrafast MirrorsRapid prototyping capabilities in designing and producing optical coatings to support the ultrafast market.Read More

Production of high laser induced damage thresholdsCompleting our suite of deposition equipment, we are developing a new Ion Beam Sputtering (IBS) System with different substrate configurations.Read More

Antireflection Coatings for Space ApplicationsSpace can be a harsh environment for optical coatings. Optimax has successfully provided antireflection (AR) coatings for a wide range of space...Read More

Designing and Selecting an Optical Cleaning ProcessEvery optical application requires a "clean" optical surface. However, what defines "clean" is subjective and is based on the needs of the application. Read More

Optical Systems: Transmissive high-energy laser opticsThere are many decisions to make when designing, specifying, manufacturing, and testing optical components for high-energy laser systems — each is a...Read More

Defect-testing optical coatings for directed energy applicationsThe use of high-power continuous wave (CW) lasers in the emerging directed energy (DE) market has put greater emphasis on the quality of optical coatings.Read More

Optimax ‐OTR Coatings for Extreme Environmental ResistanceOptimax has developed a novel optical coating (OTR‐AR). OTR coatings have been demonstrated to provide excellent resistance to latent scratching, staining...Read More

Measurement considerations when specifying optical coatingsDesign, specification, and procurement of optical coatings all benefit when the designer has a good understanding of measurement techniques and...Read More

Robotic polishing in asphere manufacturingOptimax improved the reliability of asphere polishing platforms at a demonstrated level. Download our technical paper today to learn about our results.Read More

Improving Lens Performance With Transmitted Wavefront Error TestingTolerancing optical lenses in transmission rather than reflection offers financial, performance, and delivery advantages to a given class of aspheric optics.Read More

Specifying, Manufacturing, and Measuring Aspheric Lenses – Part IIThe similarities and differences between tolerancing, manufacturing, and measuring spherical and aspheric surfaces are important.Read More

Asphere Manufacturing Considerations for the DesignerThere are many topics to consider during aspheric lens design, including geometrical restrictions that hinder the production of particular aspheric shapes....Read More

Trials and Tribulations of Optical Manufacturing: Asphere EditionOptimax Systems, Inc., a leader in quick delivery prototype optics, has been manufacturing aspheric lenses for more than 20 years. Along the way, we have...Read More

Practical Design Software Eases Asphere ManufacturabilityRecent design methods and software advances make it much easier to design aspheric surfaces that actually work in production and test by considering...Read More

Specifying, Manufacturing, and Measuring Aspheric Lenses – Part IA basic survey of specifying aspheric forms, function and manufacturing and testingRead More

How to use manufacturing statistics when tolerancing a lens systemLens design software analyzes optical tolerances by modeling a perturbed optical system to capture the effect of simultaneous changes in manufacturing and...Read More

Considerations in Manufacturing Cemented AssembliesOne design strategy for an optical system is centering two or more lenses together to build a lens assembly. However, strain in excess may cause...Read More

Optical Glass: Substitutes Versus EquivalentsSelecting the material from which a lens is made is a fundamental design consideration. In certain situations, a substitute or equivalent material may need...Read More

Specifying And Measuring Spherical Surface Irregularity ©This paper will define surface irregularity for spherical surfaces, offer information on measurement methods for testing surface irregularities, and some...Read More

Mechanical Attributes: Diameter, Center, and Edge Thickness Specification for Lens ManufactureMechanical attribute tolerances can be a major cost driver because of time and yield penalties added to the fabrication of a lens. Dimensions and their...Read More

Specifying and Measuring Slope Error of Optical SurfaceThis paper will first detail where slope error originated from, what it represents, and the role it plays in the optical performance.Read More

Role of Surface Roughness In Optical PerformanceThis paper examines the role surface roughness plays in optical system performance, discusses the components of a surface roughness specification, and...Read More

Multiwavelength Channel Femtosecond Beam Combiner with Independent GDD ControlWhen multiplexing ultrashort laser beams of different wavelengths into a single beam, the pulse shape of each color must be managed individually due to the...Read More

Optomechanical Design of the Europa Imaging System Wide Angle Camera (EIS WAC)The Jupiter environment presents many unique challenges to the optomechanical design of the Europa Imaging System (EIS) Wide Angle Camera (WAC) for NASA’s...Read More

Robotic Smoothing of Silicon MirrorsThis presentation will discuss efforts at Optimax to address this need through advancement of robotic smoothing platforms and processes.Read More

Laser Mirror Design Tradeoffs Impact Optical System PerformanceIn addition to tradeoffs between mirror reflectivity, wavefront, laser-damage threshold, and cost, new low-stress coatings offer weight, geometry, and...Read More

Leveraging 3D Printing to Streamline Precision Optical ManufacturingOptimax uses a variety of 3D printers to streamline our manufacturing processes. Download our technical paper today to learn about our results. Read More

Scaling-up freeform manufacturing: challenges and solutionsThis paper will present some of the challenges and solutions of extending freeform polishing capabilities from approximately 150 mm diameter parts to a...Read More

Design Guidelines for Predicting Stress in Cemented DoubletsThis work explores quick predictive methods for calculating potentially risky stresses and deflections in cemented doublets experiencing temperature change...Read More

Techniques for Analyzing Lens Manufacturing DataOptical designers assume a mathematically derived statistical distribution of the relevant design parameters. However, there may be significant differences...Read More

Apprenticeships for Precision Optics Manufacturing TechnicianAs U.S. manufacturing works to overcome a technical skills gap, apprenticeships are gaining favor as a post-secondary educational path.Read More

Performance of the Near-infrared Camera for the Subaru Prime Focus SpectrographThis collaboration from Johns Hopkins University, Princeton University, Aix Marseille University: CNRS, CNES, LAM, Subaru Telescope, NAOJ and Kavli...Read More

The Magellan Infrared Multiobject Spectrograph ProjectIn this presentation, Carnegie Institution for Science and University of Southern California give an in-depth look into the Magellan Infrared Multiobject...Read More

Review on the Technology Development of Optical Imaging System Based on Monolithic Multisurface OpticsIn this paper the National University of Defense Technology and Hunan Key Lab of Ultra-precision Machining Technology explore the rise of the monolithic...Read More

Using total error measurements of freeforms during manufacturing to aid in alignmentFreeform optics can enhance optical performance by reducing the number of elements, enabling lighter and more efficient systems, and by reducing aberrations.Read More

Effects of alignment errors on freeform surface irregularity and system performanceFreeform optics can be used in design to reduce optical system size and improve performance for asymmetric systems, but present new challenges for manufacturing, testing, and assembly compared to spherical or aspheric systems.Read More

Measurement of mid-spatial frequency errors on freeform optics using deflectometryFreeform optics have emerged as a new tool for optical designers and integrators. Manufacturing innovations are gradually increasing availability of...Read More

Fabrication of FreeformsOptimax has developed a robust freeform optical fabrication CNC process that includes generation, high-speed VIBE polishing, sub-aperture figure correction...Read More

Reduced Cost and Improved Figure of Sapphire Optical Components

Optimax has developed a fabrication process that not only reduces cost but also aids in producing spherical sapphire components to better figure quality.

Specification and Control of Mid-Spatial Frequency Wavefront Errors in Optical Systems

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

The Cost of Tolerancing

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.

Vibe: A New Process for High Speed Polishing of Optical Elements

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.

Tolerancing, Specifying and Measuring Spherical Radius

Two main paths for tolerancing spherical radii are power tolerance and linear radius tolerance. Both measure change relative to a nominal value, but the metrology used is the key difference.

The Manufacturing of a Multi-surface Monolithic Telescope with Freeform Surfaces

Monolithic multi-surface telescopes combined with freeform optical surfaces provide improvements in optical performance in a smaller footprint as compared to systems with spherical surfaces, while providing superior mechanical stability to traditional telescope assemblies

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