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Optics Express

Optics Express

  • Editor: C. Martijn de Sterke
  • Vol. 19, Iss. 24 — Nov. 21, 2011
  • pp: 23938–23951

Freeform manufacturing of a microoptical lens array on a steep curved substrate by use of a voice coil fast tool servo

Sebastian Scheiding, Allen Y. Yi, Andreas Gebhardt, Lei Li, Stefan Risse, Ramona Eberhardt, and Andreas Tünnermann  »View Author Affiliations


Optics Express, Vol. 19, Issue 24, pp. 23938-23951 (2011)
http://dx.doi.org/10.1364/OE.19.023938


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Abstract

We report what is to our knowledge the first approach to diamond turn microoptical lens array on a steep curved substrate by use of a voice coil fast tool servo. In recent years ultraprecision machining has been employed to manufacture accurate optical components with 3D structure for beam shaping, imaging and nonimaging applications. As a result, geometries that are difficult or impossible to manufacture using lithographic techniques might be fabricated using small diamond tools with well defined cutting edges. These 3D structures show no rotational symmetry, but rather high frequency asymmetric features thus can be treated as freeform geometries. To transfer the 3D surface data with the high frequency freeform features into a numerical control code for machining, the commonly piecewise differentiable surfaces are represented as a cloud of individual points. Based on this numeric data, the tool radius correction is calculated to account for the cutting-edge geometry. Discontinuities of the cutting tool locations due to abrupt slope changes on the substrate surface are bridged using cubic spline interpolation.When superimposed with the trajectory of the rotationally symmetric substrate the complete microoptical geometry in 3D space is established. Details of the fabrication process and performance evaluation are described.

© 2011 OSA

OCIS Codes
(220.0220) Optical design and fabrication : Optical design and fabrication
(220.1920) Optical design and fabrication : Diamond machining
(220.4000) Optical design and fabrication : Microstructure fabrication
(240.3990) Optics at surfaces : Micro-optical devices

ToC Category:
Optical Design and Fabrication

History
Original Manuscript: July 27, 2011
Revised Manuscript: August 27, 2011
Manuscript Accepted: August 27, 2011
Published: November 10, 2011

Citation
Sebastian Scheiding, Allen Y. Yi, Andreas Gebhardt, Lei Li, Stefan Risse, Ramona Eberhardt, and Andreas Tünnermann, "Freeform manufacturing of a microoptical lens array on a steep curved substrate by use of a voice coil fast tool servo," Opt. Express 19, 23938-23951 (2011)
http://www.opticsinfobase.org/oe/abstract.cfm?URI=oe-19-24-23938


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