To improve the accuracy of three-dimensional (3D) surface contour measurements of freeform optics, a two-dimensional (2D) tilt measurement sensor for confocal microscopy (CM) systems is proposed based on a double-cylindrical mirror structure. First, the proposed system is accurately modeled. Second, we introduce a modified mean–shift-based peak-extraction algorithm with a novel kernel function (MSN) because the reflectivity of the measured object and fluctuation of the light source affect the measurement accuracy. Third, a partition fitting (PF) strategy is proposed to reduce the fitting error and improve the measurement accuracy. Simulations and experiments reveal that the robustness, speed, and angular prediction accuracy of the system effectively improved as a function of MSN and PF. The developed sensor can measure the 2D tilt, where each tilt is a composition of two separate dimensions, and the mean prediction errors in the 2D plane from −10°–+10° are 0.0134° (0.067% full scale (F.S)) and 0.0142° (0.071% F.S). The sensor enables the optical probe of a traditional CM to obtain accurate and simultaneous estimates of the 2D inclination angle and spatial position coordinates of the measured surface. The proposed sensor has potential in 3D topographic reconstruction and dynamic sampling rate optimization for 3D contour detection.

A new sensor type is proposed to accurately detect the surface profiles of three-dimensional (3D) free-form surfaces. This sensor is based on the single-exposure, zero-crossing method and is used to measure position and angle simultaneously. First, the field intensity distribution in the posterior focal plane of the confocal microscope’s objective was modeled accurately. Second, because the camera needs to trigger acquisition when the surface (to be measured) reaches the focal position of the sensor, a zero-crossing prediction method based on a sliding window was proposed. Third, a fast, spatially convergent, peak-extraction algorithm was proposed to improve the accuracy and efficiency of peak extraction. This scheme reduces system installation and adjustment difficulties, and the single-exposure, zero-crossing method achieves high-speed, real-time image acquisitions. The experimental results indicate that the average error of the zero-crossing prediction system was 17.63 nm, the average error of the tilt degree measurement was 0.011° in the range of 0–8°, and the prediction error of the tilt direction measurement was 0.089° in the range of 0–360°. The sensor can measure the slope and can be potentially used for 3D surface precision detection.