Metrology data-based simulation of freeform optics

This paper describes the approach to use measurement data to enhance the simulation model for designing freeform optics. Design for manufacturing of freeform optics is still challenging, since the classical tolerancing procedures cannot be applied. In the case of spherical optics manufacturing, tolerances are more or less isotropic, and this relationship is lost in case of freeform surfaces. Hence, an accurate performance prediction of the manufactured optics cannot be made. To make the modeling approach as accurate as possible, integration of measured surface data of fabricated freeform optics in the modeling environment is proposed. This approach enables performance prediction of the real manufactured freeform surfaces as well as optimization of the manufacturing process. In our case study this approach is used on the design of an Alvarez-optics manufactured using a microinjection molding (µIM) process. The parameters of the IM process are optimized on the basis of simulation analysis resulting in optics, with a performance very close to the nominal design. Measurement of the freeform surfaces is conducted using a tactile surface measurement tool.