Effect of freeform surfaces on the volume and performance of unobscured three mirror imagers in comparison with off-axis rotationally symmetric polynomials

Geometry Selection in Three-Mirror Freeform Imagers with an Accessible Exit Pupil

Reimaging telescopes have an accessible exit pupil that facilitates stray light mitigation and matching to auxiliary optical systems. Freeform surfaces present the opportunity for unobscured reflective systems to be folded into geometries that are otherwise impracticable with conventional surface types. It is critical, however, to understand the limitations of the enabled folding geometries and choose the one that best balances the optical performance and mechanical requirements. Here, we used the aberration theory of freeform surfaces to determine the aberration correction potential for using freeform surfaces in reimaging three-mirror telescopes and established a hierarchy for the different folding geometries without using optimization. We found that when using freeform optics, the ideal folding geometry had 9× better wavefront performance compared to the next best geometry. Within that ideal geometry, the system using freeform optics had 39% better wavefront performance compared to a system using off-axis asphere surfaces, thus quantifying one of the advantages of freeform optics in this design space.

Multiconfiguration afocal freeform telescopes

An approach to designing multiconfiguration afocal telescopes is developed and demonstrated. Freeform surfaces are used to maximize the achievable diffraction-limited zoom ratio while staying in a compact volume for a two-position multiconfiguration afocal optical system. The limitations of these systems with three-mirror beam paths are discussed and subsequently overcome by introducing an additional degree of freedom. In a four-mirror beam path system, the goal of a 5x zoom ratio is achieved with a compensated exit pupil and diffraction-limited performance. A significant benefit in optical performance when using freeform surfaces is shown compared to more conventional surface types.

Design and manufacture of a large field of view thermal infrared catoptric imaging system in an αZ configuration

A geometry of a catoptric imaging system using three mirrors in an AlphaZ configuration is presented. This geometry allows large field of view and large aperture catoptric systems, useful for optronic pods as an example. A proof of concept with an 18×24 degree full field of view and a F/1.5 aperture is built using slow tool servo and 5 axis machining and characterized in the long wave infrared domain. The built system achieves nearly diffraction limited performance.

Exit pupil quality analysis and optimization in freeform afocal telescope systems

Afocal telescopes are often used as foreoptics to existing imaging systems to allow for application flexibility. To properly combine an afocal telescope with an existing imaging system, the exit pupil of the afocal telescope and the entrance pupil of the imaging system must be coincident. Additionally, the exit pupil of the afocal telescope must be well-formed; that is, it must be the correct size and shape to mitigate pupil-matching challenges. This work introduces processes for designing freeform afocal telescopes with an emphasis on understanding how to analyze and control the exit pupil quality of such systems. The included 3-mirror design examples demonstrate the advantages of using freeform surfaces in afocal systems and quantify the tradeoffs required to improve the exit pupil quality.

Implementation of a null test for freeform optics using a high-definition spatial light modulator

We report the implementation of an interferometric null test using a high-definition spatial light modulator (SLM) as a reconfigurable alternative to a computer-generated hologram. We detail the alignment process chain, including novel techniques using the SLM to project alignment fiducials on the test part. To validate the alignment protocol, we measure a mild off-axis conic with the SLM-based system and cross-validate with conventional interferometry within 30 nm root-mean-square (RMS) surface figure. Finally, we report the null test of a 65 mm clear aperture concave freeform with 91 μm peak-valley sag departure from the base sphere. The measured surface figure of the freeform is within 40 nm RMS compared to the measurement with a commercial metrology instrument.

Analysis and design of a wide-field and large-numerical-aperture compact imaging spectrometer with a freeform surface

Wide-field-of-view (FoV) Offner imaging spectrometers with freeform surfaces have been studied extensively in recent years. However, a design result with a large numerical aperture (NA) cannot be simultaneously obtained with this layout. We present the concept of a limited system in the tangential direction. Based on this insight, we present a new design method, to the best of our knowledge, based on the decenter anamorphic stop, which can achieve large NA in compact wide-FoV Offner imaging spectrometers with freeform surfaces. Compared to conventional imaging spectrometers with the same parameters, the light-gathering capacity of the decenter anamorphic stop-based imaging spectrometer is increased by more than 40%. In addition, based on the presented method, we design a compact imaging spectrometer with a wide FoV and large NA. The designed imaging spectrometer with a freeform surface has excellent performance. Finally, we fabricate and measure the freeform mirror. The surface irregularity of the freeform mirror is better than 1/30λ (λ=632.8n m). The result shows that the Offner imaging spectrometer with a freeform surface can be fabricated and will play a significant role in the fields of aeronautical and astronautical remote sensing.

Ultrafast laser stress figuring for accurate deformation of thin mirrors

Fabricating freeform mirrors relies on accurate optical figuring processes capable of arbitrarily modifying low-spatial frequency height without creating higher-spatial frequency errors. We present a scalable process to accurately figure thin mirrors using stress generated by a focused ultrafast laser. We applied ultrafast laser stress figuring (ULSF) to four thin fused silica mirrors to correct them to 10-20 nm RMS over 28 Zernike terms, in 2-3 iterations, without significantly affecting higher-frequency errors. We measured the mirrors over a month and found that dielectric-coated mirrors were stable but stability of aluminum-coated mirrors was inconclusive. The accuracy and throughput for ULSF is on par with existing deterministic figuring processes, yet ULSF doesn't significantly affect mid-spatial frequency errors, can be applied after mirror coating, and can scale to higher throughput using mature laser processing technologies. ULSF offers new potential to rapidly and accurately shape freeform mirrors.

Automatic design method of starting points of freeform off-axis reflective imaging systems of small volume

For off-axis reflective systems, there is no effective method that can obtain a small-volume starting point automatically. Reducing system volume using the optimization method is usually a difficult and cumbersome process, which usually takes the designer a long time. This paper proposes a method of designing small-volume starting points of freeform off-axis reflective imaging systems, which does not require human involvement after inputting a planar system, specifications and constraints. In the design example presented in this paper, it took only about ten minutes to obtain a small-volume starting point. The starting point obtained by this method makes the optimization process easier, takes less time of designers and more likely to succeed. In the design example, it is also demonstrated that the method has the ability of establishing small-volume starting points with different specifications, which can be used to quickly estimate the minimum volumes that systems with different specifications can achieve and provide guidance for determination of specifications and optimization.

Freeform hyperspectral imager design in a CubeSat format

A freeform pushbroom hyperspectral imager design was investigated as a combination of a freeform reflective triplet imager and a freeform reflective triplet spectrometer used in double-pass. The design operates at about F/2 with a 15-degree cross-track field-of-view and a 30 mm entrance pupil diameter. The design process led to achieving a small volume of less than 2 liters that fits comfortably within a 3U CubeSat geometry, exemplifying the compactness of this hyperspectral imager. We report the freeform sag departures and maximum slopes of the freeform surfaces, as well as the manufacturing tolerances together with an evaluation of the system stray light, all of which highlight the feasibility of a design in this class to be manufactured. This design uniquely positions itself on the landscape of compact hyperspectral imagers.

Roadmap for the unobscured three-mirror freeform design space

In rotationally symmetric lens design, there are rule-of-thumb boundaries on field-of-view and aperture for well-known design forms that provide valuable information to the designer prior to starting a design. In the design space of unobscured three-mirror imagers, freeform optics have been shown to provide a significant benefit over conventional surface shapes, but the degree to which they improve the performance for any given combination of field-of-view, entrance pupil diameter, and F-number remains unknown. Thus, designers of these systems are not afforded any pre-design information to inform their specification decisions. Here, we designed over 200 systems to establish a first-of-its-kind roadmap of specification ranges over which an unobscured three-mirror imager using freeform surfaces can achieve diffraction-limited performance in the visible spectrum. The scalability of the findings to the infrared regions of the spectrum is also addressed.

Dielectric Metalens: Properties and Three-Dimensional Imaging Applications

Recently, optical dielectric metasurfaces, ultrathin optical skins with densely arranged dielectric nanoantennas, have arisen as next-generation technologies with merits for miniaturization and functional improvement of conventional optical components. In particular, dielectric metalenses capable of optical focusing and imaging have attracted enormous attention from academic and industrial communities of optics. They can offer cutting-edge lensing functions owing to arbitrary wavefront encoding, polarization tunability, high efficiency, large diffraction angle, strong dispersion, and novel ultracompact integration methods. Based on the properties, dielectric metalenses have been applied to numerous three-dimensional imaging applications including wearable augmented or virtual reality displays with depth information, and optical sensing of three-dimensional position of object and various light properties. In this paper, we introduce the properties of optical dielectric metalenses, and review the working principles and recent advances in three-dimensional imaging applications based on them. The authors envision that the dielectric metalens and metasurface technologies could make breakthroughs for a wide range of compact optical systems for three-dimensional display and sensing.

Metaform optics: Bridging nanophotonics and freeform optics

The demand for high-resolution optical systems with a compact form factor, such as augmented reality displays, sensors, and mobile cameras, requires creating new optical component architectures. Advances in the design and fabrication of freeform optics and metasurfaces make them potential solutions to address the previous needs. Here, we introduce the concept of a metaform-an optical surface that integrates the combined benefits of a freeform optic and a metasurface into a single optical component. We experimentally realized a miniature imager using a metaform mirror. The mirror is fabricated via an enhanced electron beam lithography process on a freeform substrate. The design degrees of freedom enabled by a metaform will support a new generation of optical systems.

Verification of cascade optical coherence tomography for freeform optics form metrology

Freeform optical components enable dramatic advances for optical systems in both performance and packaging. Surface form metrology of manufactured freeform optics remains a challenge and an active area of research. Towards addressing this challenge, we previously reported on a novel architecture, cascade optical coherence tomography (C-OCT), which was validated for its ability of high-precision sag measurement at a given point. Here, we demonstrate freeform surface measurements, enabled by the development of a custom optical-relay-based scanning mechanism and a unique high-speed rotation mechanism. Experimental results on a flat mirror demonstrate an RMS flatness of 14 nm (∼λ/44 at the He-Ne wavelength). Measurement on a freeform mirror is achieved with an RMS residual of 69 nm (∼λ/9). The system-level investigations and validation provide the groundwork for advancing C-OCT as a viable freeform metrology technique.

Study of asymmetric or decentered multi-view designs for uncooled infrared imaging applications

Multi-view architectures using lens arrays can bring interesting features like 3D or multispectral imagery over single aperture cameras. Combined with super-resolution algorithms, multi-view designs are a way to miniaturize cameras while maintaining their resolution. These optical designs can be adapted for thermal infrared imagery and can thus answer the size, weight and power (SWAP) challenge with advanced imagery functions. However, in this spectral range, the choice of an uncooled microbolometer detector imposes a high numerical aperture for the system which increases the size of the optics and makes difficult a multi-channel arrangement combined with a single focal plane array (FPA). In this paper, we theoretically investigate several asymmetric or decentered multi-view designs that allow both a high aperture for the optical channels and the use of a single FPA for the sub-images. Ray-traced designs will illustrate this study and their image quality will be checked with modulation transfer functions (MTF) for different field points.

Cascade optical coherence tomography (C-OCT)

Significant advances for optical systems in terms of both performance and packaging are enabled by freeform optical components. Yet, surface form metrology for freeform optics remains a challenge. We developed and investigated a point-cloud cascade optical coherence tomography (C-OCT) technique to address this metrology challenge. The mathematical framework for the working principle of C-OCT is presented. A novel detection scheme is developed to enable high-speed measurements. Experimental results validate the C-OCT technique with the prototype setup demonstrating single-point precision of ±26 nm (∼λ/24 at the He-Ne wavelength), paving the way towards full surface measurements on freeform optical components.