Compliant grinding and polishing refers to a class of fine material processing methods relying on one or more system element being compliant with the workpiece surface in a controllable and reversible manner, thus being distinct from conventional rigid wheel grinding and polishing. The resulting surface adaptability greatly facilitates the ultra-precision machining of freeform surfaces, with a level of accuracy and productivity difficult to achieve with conventional rigid processing systems. Aiming for a comprehensive review of signal advances on this topic in the last decades, this paper introduces a multi-level compliance categorization system to sort between distinctive processes. For each category, various perspectives are explored that pertain to principles, methodologies, and physical properties such as material removal and surface integrity. Finally, relative merits are analyzed, together with a discussion of the outlook and future trends.

Compliant grinding and polishing: A review

Adaptive optics techniques have been developed over the past half century and routinely used in large ground-based telescopes for more than 30 years. Although this technique has already been used in various applications, the basic setup and methods have not changed over the past 40 years. In recent years, with the rapid development of artificial intelligence, adaptive optics will be boosted dramatically. In this paper, the recent advances on almost all aspects of adaptive optics based on machine learning are summarized. The state-of-the-art performance of intelligent adaptive optics are reviewed. The potential advantages and deficiencies of intelligent adaptive optics are also discussed.

https://www.oejournal.org/data/article/export-pdf?id=61f370bc99d881528090e6c8

Adaptive optics based on machine learning: a review

Abstract Freeform optics has become the most prominent element of the optics industry. Advanced freeform optical designs supplementary to ultra-precision manufacturing and metrology techniques have upgraded the lifestyle, thinking, and observing power of existing humans. Imaginations related to space explorations, portability, accessibility have also witnessed sensible in today’s time with freeform optics. Present-day design methods and fabrications techniques applicable in the development of freeform optics and the market requirements are focussed and explained with the help of traditional and non-traditional optical applications. Over the years, significant research is performed in the emerging field of freeform optics, but no standards are established yet in terms of tolerances and definitions. We critically review the optical design methods for freeform optics considering the image forming and non-image forming applications. Numerous subtractive manufacturing technologies including figure correction methods and metrology have been developed to fabricate extreme modern freeform optics to satisfy the demands of various applications such as space, astronomy, earth science, defence, biomedical, material processing, surveillance, and many more. We described a variety of advanced technologies in manufacturing and metrology for novel freeform optics. Next, we also covered the manufacturing-oriented design scheme for advanced optics. We conclude this review with an outlook on the future of freeform optics design, manufacturing and metrology. 

Advances in the design and manufacturing of novel freeform optics

Advances in optical engineering for future telescopes

Computer-Controlled Optical Surfacing (CCOS) has been greatly developed and widely used for precision optical fabrication in the past three decades. It relies on robust dwell time solutions to determine how long the polishing tools must dwell at certain points over the surfaces to achieve the expected forms. However, as dwell time calculations are modeled as ill-posed deconvolution, it is always non-trivial to reach a reliable solution that 1) is non-negative, since CCOS systems are not capable of adding materials, 2) minimizes the residual in the clear aperture 3) minimizes the total dwell time to guarantee the stability and efficiency of CCOS processes, 4) can be flexibly adapted to different tool paths, 5) the parameter tuning of the algorithm is simple, and 6) the computational cost is reasonable. In this study, we propose a novel Universal Dwell time Optimization (UDO) model that universally satisfies these criteria. First, the matrix-based discretization of the convolutional polishing model is employed so that dwell time can be flexibly calculated for arbitrary dwell points. Second, UDO simplifies the inverse deconvolution as a forward scalar optimization for the first time, which drastically increases the solution stability and the computational efficiency. Finally, the dwell time solution is improved by a robust iterative refinement and a total dwell time reduction scheme. The superiority and general applicability of the proposed algorithm are verified on the simulations of different CCOS processes. A real application of UDO in improving a synchrotron X-ray mirror using Ion Beam Figuring (IBF) is then demonstrated. The simulation indicates that the estimated residual in the 92.3 mm × 15.7 mm CA can be reduced from 6.32 nm Root Mean Square (RMS) to 0.20 nm RMS in 3.37 min. After one IBF process, the measured residual in the CA converges to 0.19 nm RMS, which coincides with the simulation.

Universal dwell time optimization for deterministic optics fabrication.

Metasurfaces, optics made from subwavelength-scale nanostructures, have been limited to millimeter-sizes by the scaling challenge of producing vast numbers of precisely engineered elements over a large area. In this study, we demonstrate an all-glass 100 mm diameter metasurface lens (metalens) comprising 18.7 billion nanostructures that operates in the visible spectrum with a fast f-number (f/1.5, NA=0.32) using deep-ultraviolet (DUV) projection lithography. Our work overcomes the exposure area constraints of lithography tools and demonstrates that large metasurfaces are commercially feasible. Additionally, we investigate the impact of various fabrication errors on the imaging quality of the metalens, several of which are unique to such large area metasurfaces. We demonstrate direct astronomical imaging of the Sun, the Moon, and emission nebulae at visible wavelengths and validate the robustness of such metasurfaces under extreme environmental thermal swings for space applications.

pdf/all-glass-100-mm-diameter-visible-metalens-for-imaging-the-1g4vsxb7.pdf

All-glass 100 mm Diameter Visible Metalens for Imaging the Cosmos

A transformation algorithm compensating a radius of the probe tip and pre-travel errors is proposed to improve measurement uncertainty of a coordinate measuring machine (CMM). The transformation algorithm does not only compensate a radius of the probe tip, but it also compensates a slipping displacement from the predicted contact point caused by vertical tension for each data point. The performance of the transformation algorithm was successfully demonstrated by applying the transformation algorithm to raw data of an on-axis lens and an off-axis mirror measured with the CMM and comparing them with a reference data measured with UA3P-5 having several tens of nanometer accuracy.

/pdf/touch-probe-tip-compensation-using-a-novel-transformation-4kn3a6822x.pdf

Touch Probe Tip Compensation Using a Novel Transformation Algorithm for Coordinate Measurements of Curved Surfaces

Reconfigurable freeform optical systems greatly enhance imaging performance within non-symmetric, compact, and ergonomic form factors. In this paper, several advances improve design, testing, and monitoring of these systems. Specific enhancements include definition of polynomials for fast and efficient parameterizations of vector distributions in non-circular apertures and merit based function optimization. Deflectometry system improvements enable metrology for almost any conceivable optic shape and guide deterministic optical figuring process during the coarse grinding phase by including modulated infrared sources. As a demonstration of these improvements, parametric optimization is tested with the tomographic ionized-carbon mapping experiment, a reconfigurable optical system. Other case studies and demonstrations include metrology of a fast, f/1.26 convex optic, an Alvarez lens, and real-time monitoring of an array of independently-steerable hexagonal mirror segments as well as an induction formed surface and inflatable Mylar mirror.

https://iopscience.iop.org/article/10.1088/2515-7647/abde86/pdf

Advances in reconfigurable optical design, metrology, characterization, and data analysis

The LUCI (LBT Utility Camera in the Infrared) instruments are a pair of near infrared (NIR) imagers and spectrographs for the Large Binocular Telescope (LBT) that include a set of cryogenic exchangeable focal plane masks. Although LUCI covers the NIR zJHK bands at different resolutions with existing gratings, it is not currently possible to get zJHK in a single exposure with a single LUCI which is required for some planetary science programs. To produce a simultaneous zJHK spectrum with a single LUCI, we designed a system consisting of small and simple optical elements to fit within the limited space in the focal plane mask frame to cross-disperse fixed short slits. This system, called MOBIUS (Mask-Oriented Breadboard Implementation for Unscrambling Spectra), consists of a double-folding mirror, a collimating spherical mirror with 180 mm radius of curvature, and a dispersing prism with the rear surface mirror-coated. MOBIUS disperses the input slit perpendicular to the dispersion direction of the gratings in LUCI. The resulting order separation is at least ∼2.7 arcsecond, allowing a slit length of up to ∼2.3 arcsec without mixing orders at the LUCI image plane. Since MOBIUS would be introduced into the existing light path via the exchangeable slit mask mechanism, no modification to the current LUCI instrument is needed. Eventually, binocular observations combining one of the Multi-Object Double Spectrographs (MODS) with LUCI+MOBIUS at the LBT will provide simultaneous coverage from 0.3 to 2.4 μm for studies of asteroids and other faint solar system bodies.

Modular plug-in extension enabling cross-dispersed spectroscopy for Large Binocular Telescope

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