Abstract
Free form surfaces allow elegant solutions in illumination optics. A complex function of the system can be achieved by a single optical element. Free form elements are usually manufactured by reproduction techniques, such as injection moulding of plastic. Manufacturing tolerances are crucial to maintain the required function while at the same time yielding the lowest possible price. We implemented a Monte Carlo tolerancing method for illumination systems. Tolerances include shape deviations of optical elements and assembly tolerances. In the absence of standards for free form tolerances and illumination optics tolerancing, communication between optics design, manufacturing and testing is often inefficient. In order to enable a highly automated evaluation of part measurement data to assess compliance with tolerances, we developed an approach to combine information from optics design, mechanical construction, manufacturing and testing into one continuous data chain. The research project is granted by the German Ministry of Education and Research.
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