From Event: SPIE Optical Engineering + Applications, 2018
Precision glass molding is a viable process for the cost-effective volume production of freeform optics. Process development is complex, requiring iterative trials of mold manufacture and metrology, glass mold prototyping, metrology and functional testing. This paper describes the first iteration in the development of a process for an Alvarez lens for visible light. The challenges of this optic are extremely tight band-RMS tolerances on a freeform shape over a maximum clear aperture of 45 mm, a 16:1 aspect ratio and a freeform departure of 329 micrometers. A freeform glass mold for an Alvarez lens was manufactured by coordinated-axis diamond turning in a mold substrate using a custom tool error correction method. The results of prototype precision glass molding are also reported. Mold surfaces and molded optical surfaces are analyzed with scanning white light interferometry. A surface roughness of approximately 3 nm RMS is obtained for both the mold substrate and the glass optic with high-fidelity reproduction of micro-surface structure in the glass. These measurements also identify challenging areas, particularly the presence of mid-spatial frequency errors on the optic originating from the machine thermal control system. The form of the molds was also measured with a profilometer; however, the mold surface does not agree with the expected prescription with an overall deviation in form of approximately 10 μm. The machining process is expected to have sub-micrometer error and the sources of this discrepancy are still being determined. Metrology of the glass optics is currently in progress.
Dustin Gurganus, Joseph D. Owen, Brian S. Dutterer, Spencer Novak, Alan Symmons, and Matthew A. Davies, "Precision glass molding of freeform optics," Proc. SPIE 10742, Optical Manufacturing and Testing XII, 107420Q (Presented at SPIE Optical Engineering + Applications: August 21, 2018; Published: 14 September 2018); https://doi.org/10.1117/12.2320574.
Conference Presentations are recordings of oral presentations given at SPIE conferences and published as part of the proceedings. They include the speaker's narration with video of the slides and animations. Most include full-text papers. Interactive, searchable transcripts and closed captioning are now available for most presentations.
Search our growing collection of more than 25,000 conference presentations, including many plenaries and keynotes.