We report a new route to obtaining custom freeform micro-optical components that is free from symmetry restrictions,
offering drastically lower cost and delivery times than what is required by other freeform manufacturing methods. We
describe how this process can be used to realize a complex custom optic using data generated directly from a design in
Zemax. This surface is then extracted from Zemax and fabricated using the LightForge service before being measured. A
quantitative analysis of the real optic is carried out both numerically and with the design source in Zemax, and we
present a comparison between design and fabricated part performance.
"Rapid manufacture of freeform micro-optics for high power applications", Proc. SPIE 8970, Laser 3D Manufacturing, 89700T (6 March 2014); doi: 10.1117/12.2040140; https://doi.org/10.1117/12.2040140