<title>Hybrid optics for the visible produced by bulk casting of sol-gel glass using diamond-turned molds</title>

Abstract

Recent combinations of diffractive and refractive functions in the same optical component allow designers additional opportunities to make systems more compact and enhance performance. This paper describes a research program for fabricating hybrid refractive/diffractive components from diamond-turned molds using the bulk casting of sol-gel silica glass. The authors use the complementary dispersive nature of refractive and diffractive optics to render two-color correction in a single hybrid optical element. Since diamond turning has matured as a deterministic manufacturing technology, techniques previously suitable only in the infrared are now being applied to components used at visible wavelengths. Thus, the marriage of diamond turning and sol-gel processes offers a cost-effective method for producing highly customized and specialized optical components in high quality silica glass. With the sol-gel casting method of replication, diamond-turned mold costs can be shared over many pieces. Diamond turning takes advantage of all of the available degrees of freedom in a single hybrid optical element: aspheric surface to eliminate spherical aberration, kinoform surface for control of primary chromatic aberration, and the flexibility to place the kinoform on non-planar surfaces for maximum design flexibility. The authors discuss the critical issues involved in designing the hybrid element, single point diamond-turning the mold, and fabrication in glass using the sol-gel process.