Table of Contents

Preface

1 Introduction

Aizhong Zhang and Richard N. Youngworth

References

2 Optical Materials

Ralf Jedamzik, Uwe Petzold, Frank Nürnberg, Bodo Kühn, and Gordon von der Gönna

2.1 Introduction

2.2 Optical Glass Production

     2.2.1 What is optical glass?

     2.2.2 Raw materials

     2.2.3 Melting and coarse annealing

     2.2.4 Fine annealing

     2.2.5 Refractive index measurement

     2.2.6 Refractive index homogeneity measurement

     2.2.7 Refractive index homogeneity: striae

     2.2.8 Transmittance measurement

     2.2.9 Stress birefringence measurement

     2.2.10 Bubble and inclusion measurement

     2.2.11 Other properties

2.3 Fused Silica Production

     2.3.1 Properties of fused silica

     2.3.2 Making of fused quartz and fused silica

     2.3.3 Homogenization of quartz glass

     2.3.4 Shaping and forming of quartz glass

     2.3.5 Doping quartz glass

     2.3.6 Quartz glass for applications in the near-infrared

     2.3.7 Laser-induced damage threshold of quartz glass

     2.3.8 Applications

2.4 Crystalline Materials Production

     2.4.1 History

     2.4.2 The crystalline state

     2.4.3 Crystal growth

     2.4.4 Optical ceramics

     2.4.5 Post-growth heat treatment

     2.4.6 Properties and qualities

2.5 Optical Material Trends

References

3 Optical Fabrication

Jessica DeGroote Nelson

3.1 Introduction

3.2 Traditional Fabrication Methods

     3.2.1 Cast iron lapping

     3.2.2 Conventional or pitch polishing

3.3 CNC Optics Manufacturing

     3.3.1 Spherical CNC generation

     3.3.2 Deterministic small tool polishers

     3.3.3 Mid-spatial frequency smoothing methods

3.4 Special Considerations for Aspheres and Freeforms

     3.4.1 Aspheres

     3.4.2 Freeforms

3.5 Concluding Remarks

References

4 Metrology

Daewook Kim, Isaac Trumper, and Logan R. Graves

4.1 Introduction

4.2 Standard Opto-Mechanical Metrology

     4.2.1 Coordinate measuring machines

     4.2.2 Machine vision

     4.2.3 Structured light projection

     4.2.4 Laser tracker

     4.2.5 Infrared scanning system

4.3 Precision Process Guiding Metrology

     4.3.1 Contact stylus profilometry

     4.3.2 Non-contact slope sensor scanning

     4.3.3 On-machine metrology

4.4 High-Precision Quality Check or Verification Metrology

     4.4.1 Birefringence measurements

     4.4.2 Swing arm profilometry

     4.4.3 Deflectometry

     4.4.4 Null interferometry

     4.4.5 Instantaneous dynamic interferometry

     4.4.6 Microscopic white-light interferometry

4.5 Concluding Remarks

References

5 Optical Coatings

Ronald R. Willey

5.1 Introduction

5.2 The New Century

     5.2.1 Better understanding

     5.2.2 Design

     5.2.3 Materials

     5.2.4 Equipment

     5.2.5 Masking for uniformity

     5.2.6 Monitoring and control

     5.2.7 Processes

     5.2.8 Index versus thickness

5.3 Conclusions

References

6 Infrared Optical Systems

Adam Phenis and Jason Mudge

6.1 Introduction

6.2 New Applications

     6.2.1 Industrial imaging

     6.2.2 Defense

     6.2.3 Science

6.3 Component Development

     6.3.1 Infrared sensing

     6.3.2 Infrared sources

6.4 Acknowledgments

References

7 Polymer Optics

Robert Parada, Jr., Douglas Axtell, and Dan Morgan

7.1 Introduction

7.2 Polymer Materials

7.3 Optical Design Considerations

7.4 Small-Volume Manufacturing

7.5 Large-Volume Manufacturing

7.6 Metrology Considerations

7.7 Ancillary Services

     7.7.1 Gate vestige removal

     7.7.2 Optical thin film coating

     7.7.3 Alignment and joining

     7.7.4 Stress reduction

7.8 Emerging Techniques and Applications

     7.8.1 Micro-optics

     7.8.2 Photonics

     7.8.3 Asymmetric form factors

     7.8.4 Novel materials

     7.8.5 Healthcare

References

8 Optical Fibers and Optical Fiber Assemblies

Devinder Saini, Kevin Farley, and Brian Westlund

8.1 Optical Fibers

     8.1.1 Preform manufacturing

     8.1.2 Fiber draw

     8.1.3 Fiber testing capabilities

     8.1.4 Advanced fibers

8.2 Optical Fiber Applications and Assemblies

     8.2.1 Applications

     8.2.2 Mode mixing and de-speckling

     8.2.3 Anti-reflection technologies

     8.2.4 Assembly design considerations

     8.2.5 1D and 2D arrays

     8.2.6 High-power design considerations

References

9 Diffractive- and Micro-structured Optics

Tasso R. M. Sales and G. Michael Morris

9.1 Introduction

9.2 Fabrication of Surface-Relief Masters

     9.2.1 Single-point diamond turning (SPDT)

     9.2.2 Optical and E-beam lithography

     9.2.3 Laser pattern generation

     9.2.4 Reactive ion etching

     9.2.5 Nickel electroform tooling

9.3 High-Volume Manufacturing Processes

     9.3.1 Polymer-on glass wafers

     9.3.2 Roll-to-roll manufacturing

9.4 Diffractive Lenses in Broadband Imaging Systems

     9.4.1 Diffractive lens fundamentals

     9.4.2 Diffractive/refractive (hybrid) achromatic lenses

     9.4.3 Multi-layer diffractive optical elements

     9.4.4 Multi-order diffractive lenses

     9.4.5 Multifocal diffractive ophthalmic lenses

9.5 Markets for Micro-Structured Optics

     9.5.1 Gesture recognition and 3D imaging/sensing systems

     9.5.2 Display and image projection systems

     9.5.3 Solid-state lighting

9.6 Summary

References

10 Illumination Optics

Henning Rehn and Julius Muschaweck

10.1 Introduction

10.2 Fields of Application

     10.2.1 Indoor lighting

     10.2.2 Outdoor lighting

     10.2.3 Automotive lighting

     10.2.4 Medical lighting

     10.2.5 Airfield lighting

     10.2.6 Entertainment lighting

     10.2.7 Data and video projection

     10.2.8 Flat panel displays

     10.2.9 Smartphones and smart watches

     10.2.10 Solar

     10.2.11 Freeform optics

     10.2.12 Trends after 2000

10.3 Light Sources and Their Fabrication

     10.3.1 Legacy light sources

     10.3.2 Rise of LED technology

10.4 Optical Components for Illumination and Their Fabrication

     10.4.1 Standard lenses

     10.4.2 TIR lenses and related collimators

     10.4.3 Fresnel lenses

     10.4.4 Compound concentrators

     10.4.5 Reflectors

     10.4.6 Light guides

     10.4.7 Homogenizers

     10.4.8 Sheets

10.5 Prototype Technologies

10.6 Outlook

References

Preface

This book summarizes some of the critical changes that have impacted optical system manufacturing from 2000 to 2020. It evaluates new manufacturing techniques with growing popularity and identifies future trends. The chapters provide a snapshot of the field that conveys the basics of current manufacturing capabilities and promising new techniques. Other topics reviewed include optical materials, optical fabrication, metrology, optical coatings, infrared optical systems, polymer optics, fiber optics, diffractive- and micro-structured optics, and illumination optics. This book is suitable for beginner optical engineers learning about the optics industry and for advanced professionals staying up-to-date with various subfields of optics.

Aizhong Zhang
Richard N. Youngworth
Editors
August 2021