Complex Optical Surfaces Research Articles

Micro-structuring of glassy carbon for precision glass molding of binary diffractive optical elements

Precision glass molding is a more cost efficient process for the large volume manufacturing of highly complex optical surfaces than direct manufacturing. Glassy carbon (GC) molds are used for precision glass molding, because they can be operated at temperatures up to 2000°C. Used today mainly for manufacturing aspheric lenses, we consider here material technology for diffractive optical element (DOE). For diffractive optics the surface structuring is in the micrometer range and a surface roughness Ra lower than 20 nm is required. We introduce a reactive ion etching process with a titanium hard mask. Fused silica (FS) molds with identical optical functionality were fabricated for comparison. All molds were used for precision glass molding of a low Tg glass L-BAL42. We will compare GC and FS as mold materials in terms of quality and robustness. Optical performance measurements of the molded glass DOEs are shown and are in good agreement with the theoretical predictions. The results confirm that precision glass molding based on GC molds is a very promising technology to economically fabricate small structures in glass for DOEs.

Tool path generation for slow tool servo turning of complex optical surfaces

Slow tool servo (STS) turning is a superior process for machining precision and complicated surfaces that has already gained a wide application especially in optics industry. However, it is lack of systematically study of tool path generation for STS turning of complex surfaces, especially of interpolation among discrete cutting location points. This paper presents a comprehensive tool path generation strategy for STS turning of complex surfaces, including cutting location point optimized planning, trajectory interpolation, and machining simulation. First, cutting contact point discretization and tool geometry compensation were analyzed during cutting location point planning procedure. Second, Hermite segment interpolation used by trajectory interpolation was analyzed, and three position-velocity-time (PVT) entrance parameters algorithms were put forward, i.e., the constant speed method, area method, and the three points method. Third, the machining simulation was carried out to evaluate the performance of the generated tool path. The analysis of Z-axis motion characteristics indicated that both the area method (c = 2/3) and three points method can meet the requirements of smooth velocity of Z-axis when the Z-axis reciprocating frequency is similar to the C-axis rotating frequency. From the viewpoint of acceleration, the three points method is much better than the area method when the Z-axis reciprocating frequency is significantly greater than the C-axis rotary frequency. Finally, a progressive addition lens surface was fabricated to prove the feasibility of the proposed tool path generation method.

Topographic optical profilometry by absorption in liquids

Optical absorbance within a liquid is used as a photometric probe to measure the topography of optical surfaces relative to a reference. The liquid fills the gap between the reference surface and the measuring surface. By comparing two transmission images at different wavelengths we can profile the height distribution in a simple and reliable way. The presented method handles steep surface slopes (<90°) without difficulty. It adapts well to any field of view and height range (peak to valley). A height resolution in the order of the nanometer may be achieved and the height range can be tailored by adapting the concentration of water soluble dyes. It is especially appropriate for 3D profiling of transparent complex optical surfaces, like those found in micro-optic arrays and for Fresnel, aspheric or free-form lenses, which are very difficult to measure by other optical methods. We show some experimental results to validate its capabilities as a metrological tool and handling of steep surface slopes.

Hybrid optical (freeform) components—functionalization of nonplanar optical surfaces by direct picosecond laser ablation

The performance of optical systems is typically improved by increasing the number of conventionally fabricated optical components (spheres, aspheres, and gratings). This approach is automatically connected to a system enlargement, as well as potentially higher assembly and maintenance costs. Hybrid optical freeform components can help to overcome this trade-off. They merge several optical functions within fewer but more complex optical surfaces, e.g., elements comprising shallow refractive/reflective and high-frequency diffractive structures. However, providing the flexibility and precision essential for their realization is one of the major challenges in the field of optical component fabrication. In this article we present tailored integrated machining techniques suitable for rapid prototyping as well as the fabrication of molding tools for low-cost mass replication of hybrid optical freeform components. To produce the different feature sizes with optical surface quality, we successively combine mechanical machining modes (ultraprecision micromilling and fly cutting) with precisely aligned direct picosecond laser ablation in an integrated fabrication approach. The fabrication accuracy and surface quality achieved by our integrated fabrication approach are demonstrated with profilometric measurements and experimental investigations of the optical performance.

Tool path generation for ultra-precision machining of free-form surfaces

The generation of tool paths for ultra-precision machining is still a limiting factor in the manufacturing of parts with complex optical surfaces. In conventional machining as well as in complex five axes machining the application of CAD- and CAM-software for the generation of tool paths is state of the art. But these software solutions are not able to generate tool paths according to the high requirements of ultra-precision machining. This paper describes possible ways to generate tool paths for ultra-precision machining when the optical surface can be analytically described or when the surface data is derived from optical design software. Ultra-precision milling experiments with different tool paths have been carried out and the quality of the machined geometry has been evaluated concerning the achievable form accuracy.

Complex Optical Surfaces Formed by Replica Molding Against Elastomeric Masters

Complex, optically functional surfaces in organic polymers can be fabricated by replicating relief structures present on the surface of an elastomeric master with an ultraviolet or thermally curable organic polymer, while the master is deformed by compression, bending, or stretching. The versatility of this procedure for fabricating surfaces with complex, micrometer- and submicrometer-scale patterns was demonstrated by the production of (i) diffraction gratings with periods smaller than the original grating; (ii) chirped, blazed diffraction gratings (where the period of a chirped grating changes continuously with position) on planar and curved surfaces; (iii) patterned microfeatures on the surfaces of approximately hemispherical objects (for example, an optical surface similar to a fly's eye); and (iv) arrays of rhombic microlenses. These topologically complex, micropatterned surfaces are difficult to fabricate with other techniques.