Short answer

Invest in or develop advanced metrology solutions that are non-contact, universal, and capable of high accuracy for complex geometries to support the production of next-generation optical components.

Field: Final Production
Source: Data Archiving and Networked Services (DANS) (2009)
Method: Experimental design and realization of a custom metrology instrument.
Evidence: Strong effect

A novel cylindrical scanning metrology instrument enables high-accuracy, non-contact measurement of large freeform optical surfaces, crucial for advanced optical system manufacturing. This final production research insight is drawn from a 2009 study published in Data Archiving and Networked Services (DANS). Using Experimental design and realization of a custom metrology instrument., researchers explored how this design variable affects real-world outcomes. The key design takeaway: Invest in or develop advanced metrology solutions that are non-contact, universal, and capable of high accuracy for complex geometries to support the production of next-generation optical components.

Study

Final ProductionHigh ImpactStrong effect

30nm Uncertainty Achieved in Non-Contact Freeform Optics Metrology for Ø500mm Components

A novel cylindrical scanning metrology instrument enables high-accuracy, non-contact measurement of large freeform optical surfaces, crucial for advanced optical system manufacturing.

Data Archiving and Networked Services (DANS) · 2009

Key Findings

01The developed measurement machine is capable of universal, non-contact, and fast measurement of freeform optics up to Ø500 mm.
02The achieved measurement uncertainty is 30 nm (2s).
03The cylindrical scanning setup with an optical distance probe minimizes dynamics and is sensitive to errors in a 2D plane.

Application

Design takeaway

Invest in or develop advanced metrology solutions that are non-contact, universal, and capable of high accuracy for complex geometries to support the production of next-generation optical components.

How to apply

When designing or specifying metrology for freeform or aspherical optical components, prioritize non-contact methods and investigate error compensation techniques to achieve sub-micron or nanometer level uncertainties.

Project actions

01Consider the limitations of contact vs. non-contact measurement methods for your design.
02If measuring complex surfaces, investigate how to minimize measurement errors.

Method & Evidence

AimTo design, realize, and test a non-contact metrology instrument capable of universal, fast measurement of freeform optics up to Ø500 mm with an uncertainty of 30 nm (2s).

MethodExperimental design and realization of a custom metrology instrument.

ProcedureA cylindrical scanning setup with an optical distance probe was designed and implemented. The system utilizes a metrology frame to minimize stage errors and orients the probe perpendicular to the surface's best-fit to reduce sensitivity to tangential errors. The motion system provides 4 degrees of freedom (radial, vertical, and inclination) for probe positioning relative to the product mounted on an air bearing spindle.

ContextManufacturing of high-precision optical components, specifically freeform optics.

Variables

IVDesign of the metrology instrument (cylindrical scanning, probe orientation, metrology frame).

DVMeasurement uncertainty, measurement speed, measurement volume.

CVProduct size (up to Ø500 mm), type of surface (freeform optics), environmental conditions (implied for achieving low uncertainty).

Strengths & Limitations

Strengths

+Addresses a critical need for metrology in freeform optics manufacturing.
+Achieves high accuracy (30nm) for a large measurement volume.
+Employs innovative design features like a metrology frame for error reduction.

Limitations

Replicating a 30nm uncertainty system is extremely challenging due to the need for highly precise components, environmental control, and sophisticated calibration procedures.

Reliability & validity

Reliability would be assessed by repeated measurements of the same surface under identical conditions. Validity would be established by comparing the instrument's measurements against a known standard or a different, established metrology technique.

Think critically

How might the 'universal' nature of this metrology system be limited in practice when dealing with extremely diverse freeform surface types or materials?

Design Principles

"For complex geometries, non-contact metrology with error compensation strategies is essential for achieving high measurement accuracy and enabling advanced manufacturing."

The development of precise metrology is a critical bottleneck in the production of advanced optical components. This research demonstrates a viable solution for measuring complex freeform surfaces, which are increasingly used to improve optical performance and reduce system size and weight.

What This Means for Your Design

This research created a special machine that can measure the shape of very precise, curved lenses (called freeform optics) without touching them. It can measure large lenses with incredibly high accuracy, which is important for making better cameras, telescopes, and other optical devices.

How to use in your project

1.Reference this study when discussing the importance of metrology in the production of precision components, especially for advanced geometries.
2.Use the findings on uncertainty and measurement volume to justify the selection or development of specific measurement techniques in your design project.

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Quick Cite

Paragraph starter

The development of advanced metrology is critical for the production of complex components like freeform optics. Research by Henselmans (2009) demonstrated a non-contact measurement machine achieving 30nm uncertainty for Ø500mm freeform surfaces, highlighting the importance of specialized measurement systems in enabling high-precision manufacturing.

Source

Data Archiving and Networked Services (DANS)

Non-contact measurement machine for freeform optics

journal · 2009

View source

Questions About This Research

What does the research say about 30nm uncertainty achieved in non-contact freeform optics metrology for ø500mm components?: Invest in or develop advanced metrology solutions that are non-contact, universal, and capable of high accuracy for complex geometries to support the production of next-generation optical components. Evidence: Data Archiving and Networked Services (DANS) (2009).
Why does "30nm Uncertainty Achieved in Non-Contact Freeform Optics Metrology for Ø500mm Components" matter for design?: The development of precise metrology is a critical bottleneck in the production of advanced optical components. This research demonstrates a viable solution for measuring complex freeform surfaces, which are increasingly used to improve optical performance and reduce system size and weight.
How can designers apply this research?: Invest in or develop advanced metrology solutions that are non-contact, universal, and capable of high accuracy for complex geometries to support the production of next-generation optical components.
What were the main findings?: The developed measurement machine is capable of universal, non-contact, and fast measurement of freeform optics up to Ø500 mm.. The achieved measurement uncertainty is 30 nm (2s).. The cylindrical scanning setup with an optical distance probe minimizes dynamics and is sensitive to errors in a 2D plane.
What research method was used?: Experimental design and realization of a custom metrology instrument..
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2009 journal from Data Archiving and Networked Services (DANS).
What should I do differently in my next project?: When designing or specifying metrology for freeform or aspherical optical components, prioritize non-contact methods and investigate error compensation techniques to achieve sub-micron or nanometer level uncertainties.
What are the limitations?: The specific probe range (5 mm) might limit its application to surfaces with less extreme curvature variations without re-positioning. The reliance on an air bearing spindle implies specific environmental and maintenance requirements.