No abstract

Optical freeform surfaces are of great advantage in excellent optical performance and integrated alignment features. It has wide applications in illumination, imaging and non-imaging, etc. Machining freeform surfaces on infrared (IR) materials with ultra-precision finish is difficult due to its brittle nature. Fast tool servo (FTS) assisted diamond turning is a powerful technique for the realization of freeform optics on brittle materials due to its features of high spindle speed and high cutting speed. However it has difficulties with large slope angles and large rise-and-falls in the sagittal direction. In order to overcome this defect, the balance of the machining quality on the freeform surface and the brittle nature in IR materials should be realized. This paper presents the design of a near-rotational freeform surface (NRFS) with a low non-rotational degree (NRD) to constraint the variation of traditional freeform optics to solve this issue. In NRFS, the separation of the surface results in a rotational part and a residual part denoted as a non-rotational surface (NRS). Machining NRFS on germanium is operated by FTS diamond turning. Characteristics of the surface indicate that the optical finish of the freeform surface has been achieved. The modulation transfer function (MTF) of the freeform optics shows a good agreement to the design expectation. Images of the final optical system confirm that the fabricating strategy is of high efficiency and high quality. Challenges and prospects are discussed to provide guidance of future work.

Freeform optics has been regarded as the next generation of the optical components, especially those with non-circular apertures are playing an increasingly significant role in scanning field and specialized optical system. However, there still exist challenges to machine non-circular optical freeform surface. This paper is focused on highly efficiently generating freeform surfaces with optical surface quality by ultra-precision turning using a fast tool servo (FTS). A systematic strategy of machining smooth freeform surfaces with rectangular aperture is proposed in this paper. The contour of freeform optics is decomposed and assigned to the motions of slide and FTS back-and-forth. An optimized model is established for deriving the profile of the rotational component to cater for the capacity of FTS. Tool path reconstruction is carried out to generate a smooth tool trajectory and modified the contour to cater for the stroke of FTS. Simulation is adopted to analyze the machining property of a typical rectangular freeform surface. A rectangular freeform surface is efficiently machined via the proposed method, where a micron level profile error and nanometric finish in Ra are realized. Characteristics of reflection are analyzed via experiment and simulation. Prospects of such machining approach are discussed to provide guidance to future study.

Phase compensation is a critical step for the optical measuring system using spatial light modulator (SLM). The wavefront distortion from SLM is mainly caused by the phase modulation non-linearity and non-uniformity of SLM’s physical structure and environmental conditions. A phase modulation characteristic calibration and compensation method for liquid crystal on silicon spatial light modulator (LCoS-SLM) with a Twyman-Green interferometer is illustrated in this study. A method using two sequences of phase maps is proposed to calibrate the non-uniformity character over the whole aperture of LCoS-SLM at pixel level. A phase compensation matrix is calculated to correct the actual phase modulation of the LCoS-SLM and ensure that the designed wavefront could be achieved. Compared with previously known compensation methods, the proposed method could obtain the phase modulation characteristic curve of each pixel on the LCoS-SLM, rather than a mono look-up table (LUT) curve or multi-LUT curves corresponding to an array of blocks over the whole aperture of the LCoS-SLM. The experiment results show that the phase compensation precision could reach a peak-valley value of 0.061λ in wavefront and this method can be applied in generating freeform wave front for precise optical performance.

The two peaks characteristic of yellow and blue light in the spectrum of dual-wavelength white light emitting diodes (LEDs) introduce distinctive features to the interference signal of white light scanning interferometry (WLSI). The distinctive features are defined as discontinuities, so that the fringe contrast function cannot be modeled as a single Gaussian function, and causes the interferogram to have uneven distribution of fringes of different orders in the scanning interferometer. This phenomenon leads to the low accuracy of the zero-order fringe position in the envelope calculation, which affects the repeatability and accuracy of the interferometry. This paper proposes a new surface recovery algorithm based on the Hilbert phase envelope and adjacent reference points calculation, which can effectively overcome the influence of the discontinuous signal of dual-wavelength LED white light interference on the three-dimensional reconstruction of WLSI measurements. The reliability of the algorithm is verified by experiments, and the measurement accuracy of LED WLSI system is evaluated.