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AI-enhanced integrated surface metrology

Lead Research Organisation: University of Nottingham
Department Name: Faculty of Engineering

Abstract

The world is experiencing the first stages of a digital industrial revolution: Industry 4.0. However, current digital quality control solutions are not delivering in terms of speed, capability, efficiency or futureproofing. An essential part of manufacturing is quality control, which is achieved through measurement. One of the most important measurands for quality control is the surface of the part; both shape and fine-scale topography are critical when considering tolerances, assembly and ultimately functionality. But current integrated surface measurement technologies are too slow and have little flexibility under variable processing conditions. Measurements are taken after manufacture or by slowing down the process - compromising the all-important throughput. To take surface measurement from lab to application can require speed increases of several orders of magnitude, and this is often beyond the capability of current technology. However, I have demonstrated that these challenges can be tackled using an emerging approach: information-rich metrology - the use of a priori information to enhance the measurement process by optimising what needs to be measured, so increasing the spatial bandwidth but decreasing the measurement time. Such optimisation generally requires complex physics models of the measurement; this is where a recent revolution comes to the rescue: machine learning, which I will use to combine newly developed physics models with a priori information to produce enhanced measurement systems that are an integral, real-time, and constantly learning part of the manufacturing process. This is not a proposal to make incremental developments; rather I seek to transform the field by combining the advances of three fields (basic physics, machine learning and metrology) - a binding energy approach that will be more than the sum of the parts. The proposed project will revolutionise digital quality, making measurement a seamless, yet constantly evolving part of manufacturing.

Publications

10 25 50
 
Description The accuracy of Beckmann-Kirchhoff (BK) model when modelling scattered fields from surfaces is limited to slope angles less than 38° and small radii of curvature (<10). This is established by studying the difference between amplitudes obtained using the BK model and boundary element method (BEM) averaged over different scattering angles.
Efficient solutions without very heavy numerical computations are possible using linear theory of imaging of surface but they are limited to smooth surface with low curvatures and do not account for multiple scattering. Numerical 3D solutions based on finite elements methods were found to be very accurate but are extremely computationally expensive. Maxwell-equations-based BEM also solve 3D problems but show higher errors compared to 2D BEM solutions based on Kirchhoff-Helmholtz.
Light polarisation was found to affect fringe visibility, signal strength, phase shift, edge sensitivity.
Reconstruction methods, required to extract surface heights from fringe data, are important for interferometric surface topography measurements. Noise level is found to affect the performance of reconstruction methods including continuous wavelet transform, Hilbert transform, Fourier domain analysis and convolutional neural network.
Training statistical models on typical surface topography measurement data can be very computationally expensive as sizes of covariance kernels increase exponentially (standard Gaussian processes scales cubically with the number of data points). Some existing techniques to improve scalability such as sparse approximation, dimensionality reduction and kernel approximation methods risk losing important information about the surface modelled. The use of optimised localized models that consider surface correlation lengths was found to retain detailed surface characteristics when modelling surfaces.
Exploitation Route The method could be commercialised
Sectors Manufacturing

including Industrial Biotechology

 
Description The findings have been published, presented at conferences and we had discussions with potential industrial users
First Year Of Impact 2025
Sector Manufacturing, including Industrial Biotechology
Impact Types Economic

 
Description Calibration and correction of optical topography measuring technology
Amount £112,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 03/2019 
End 04/2020
 
Description High Throughput Laser Array Based Additive Manufacturing
Amount £1,798,592 (GBP)
Funding ID EP/X010929/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2023 
End 12/2025
 
Title Physics-based virtual coherence scanning interferometer for surface measurement 
Description This work presents the first virtual Coherence Scanning Interferometer (CSI) capable of accurately predicting measurement results for surfaces with complex topography using a specific real instrument. The virtual instrument is built on physical models derived from first principles, incorporating surface-scattering models, three-dimensional imaging theory, and error-generation models. By simulating the influences of various error sources directly in the interferogram before reconstructing the surface, the virtual instrument closely replicates the operation of a real CSI system. Additionally, the experimentally determined three-dimensional transfer function of a specific instrument configuration is integrated to enhance the fidelity of virtual measurements. The method is validated through experimental comparisons, ensuring that the virtual instrument can provide reliable uncertainty evaluation for different surface types. Ongoing work focuses on developing more advanced error source models and improving the surface reconstruction process to further enhance measurement accuracy. 
Type Of Material Improvements to research infrastructure 
Year Produced 2021 
Provided To Others? Yes  
Impact The development of this virtual CSI instrument has significant implications for task-specific uncertainty evaluation in surface and dimensional metrology. By enabling realistic simulations of measurements under controlled conditions, this tool provides a deeper understanding of how error sources influence measurement results, allowing for more accurate error prediction and correction strategies. The ability to replicate the behavior of a real instrument without requiring extensive experimental measurements reduces the need for costly and time-consuming trials, making metrology processes more efficient. This method enhances measurement traceability, supports instrument calibration, and contributes to improving the accuracy and reliability of surface topography measurements across various scientific, industrial, and manufacturing applications. Ongoing advancements in error source modeling and surface reconstruction will further refine the virtual instrument, making it an even more powerful tool for metrology research and industrial applications. 
URL https://www.light-am.com/article/doi/10.37188/lam.2021.009
 
Title Scalable stochastic modelling of surface topography data using autocorrelation information 
Description This research method addresses the prevailing drawback of stochastic surface modelling methods, such as Gaussian process-based approaches, which is scalability. Exhaustive increases in computational demand occur when the size of data increases, challenging computational capacity. Improvement in scalability is suggested by using surface autocorrelation lengths to ensure more efficient use of computational resources when modelling surfaces. 
Type Of Material Improvements to research infrastructure 
Year Produced 2024 
Provided To Others? Yes  
Impact The method makes it possible to model or replicate surface topography measurements taking into account dynamic and stochastic effects. It is being applied to virtual surface topography measurement instruments for surface height inferences with confidence intervals. 
URL https://www.researchgate.net/publication/385654507_Stochastic_modelling_of_surface_topography_data_u...
 
Title Dataset for 'Comparison of approximate methods for modelling coherence scanning interferometry' 
Description This research focuses on the modelling of Coherence Scanning Interferometry (CSI) for surface topography measurement, a widely used optical technique in both industrial and biomedical applications. The dataset includes measured topographies of various surfaces, such as different sinusoids, two posts, and a step height, using three approximate physics-based models: elementary Fourier optics, universal Fourier optics, and foil models. These models rely on scalar diffraction theory and the optical system's imaging properties to simulate CSI surface measurements. The dataset allows for comparisons between the results generated by these methods and illustrates the effectiveness and agreement between the three models in predicting topography information from the interference fringes. 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
Impact The development of this research model and dataset provides valuable insights into the accuracy and applicability of different approximation methods for CSI surface topography measurement. By comparing the measured topographies of diverse surface geometries calculated using elementary Fourier optics, universal Fourier optics, and foil models, the research demonstrates the potential for using these approximate models in practical CSI applications with minimal computational effort. The results underscore the agreement between the models, contributing to a better understanding of how each approach can be used to predict interference fringes and extract topography information efficiently. This work has a significant impact on improving CSI modelling techniques, aiding in the development of faster and more reliable surface measurement methods for a wide range of industrial and biomedical surfaces. 
URL https://zenodo.org/doi/10.5281/zenodo.11454644
 
Title Dataset for 'Comparison of coherence scanning interferometry, focus variation and confocal microscopy for surface topography measurement' 
Description The original measurement data shown in Figures 1 to 3 of the Euspen conference publication: Comparison of coherence scanning interferometry, focus variation and confocal microscopy for surface topography measurement, https://www.euspen.eu/knowledge-base/ICE23170.pdf.  Acknowledgements  The authors would like to thank the UKRI Research England Development (RED) Fund for funding this work via the Midlands Centre for Data-Drive Metrology. This work was supported by the European Metrology Programme for Innovation and Research (EMPIR) project (TracOptic, 20IND07) and the European Union (ERC, AI-SURF, 101054454). 
Type Of Material Database/Collection of data 
Year Produced 2023 
Provided To Others? Yes  
Impact This research provides valuable comparative insights into the strengths and limitations of CSI, FV, and CM for measuring surface topography. The dataset demonstrates that CSI offers superior vertical resolution with significantly lower measurement noise, making it ideal for precise surface measurements with sub-nanometer resolution. The findings also highlight that CM can measure surfaces with higher slope angles (up to 30°) due to its higher numerical aperture compared to CSI, making it more suitable for tilted surfaces. Moreover, the dataset shows that FV is highly effective for measuring complex additive manufactured (AM) surfaces, despite limitations in reconstructing smooth surfaces. The impact of this work lies in providing a comprehensive understanding of how these technologies can be selected for specific surface features, improving decision-making in choosing the appropriate technology for different industrial and manufacturing applications, especially for complex AM surfaces. 
URL https://zenodo.org/doi/10.5281/zenodo.10365872
 
Title Dataset for 'Quantitative investigation of the validity conditions for the Beckmann-Kirchhoff scattering model' 
Description This research focuses on the development and comparison of two models-Boundary Element Method (BEM) and Beckmann-Kirchhoff (BK) scattering model-to evaluate light scattering from surfaces with varying geometries. The dataset consists of simulated scattered fields from various sinusoidal and combined sinusoidal surface profiles, with a focus on different surface specifications such as slope angles (SA) and curvatures. The BEM model, which is rigorous and accounts for polarization and multiple scattering effects, is used to simulate the scattered light from surfaces with complex geometries. The BK model, an approximate model, is also applied to predict the scattering from surfaces with simpler, slowly varying features. The research compares the results of these models to quantify the validity conditions of the BK model, particularly in relation to surface features with high slope angles and small radii of curvature. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
Impact The development of this research model and dataset has significant implications for improving the accuracy of light scattering predictions from complex surface geometries. By quantifying the validity conditions for the BK model based on surface specifications such as slope angles and curvature, this work provides essential insights into the limitations and conditions under which approximate models can be reliably used. The findings contribute to better understanding the applicability of the BK model in real-world measurements of surface topography, especially in optical metrology and instrumentation. The impact of this work lies in its potential to enhance the precision of models used for surface characterization, leading to improvements in error analysis, uncertainty estimation, and the development of more accurate measurement techniques for surfaces with complex geometries. 
URL https://zenodo.org/doi/10.5281/zenodo.11477538
 
Description Collaboration with DFM on numerical modelling and systematic error analysis for the surface topography measuring instruments 
Organisation Danish National Metrology Institute (DFM)
Country Denmark 
Sector Public 
PI Contribution Our team at the university of Nottingham contributed to the collaboration within the TracOptic project, a Horizon Europe initiative focused on traceable industrial 3D roughness and dimensional measurement using optical 3D microscopy and optical distance sensors. Our primary role involved developing numerical models that predict the response for complex surface geometries and enabling their use in systematic error analysis and correction. We explored multiple approaches to model light diffraction and scattering, employing both approximate methods and rigorous solutions of Maxwell's equations. Additionally, we modelled a coherence scanning instrument using both approximate and rigorous scattering models to analyse systematic errors and enhance measurement accuracy.
Collaborator Contribution Our partners contributed by providing their own advanced models for coherence scanning interferometry, as well as models for focus variation and confocal microscopy. They played a crucial role in validating and comparing results by implementing different modelling techniques and analysing the effects of various error sources. This collaborative effort ensured a comprehensive comparison between different virtual models and experimental data from real instruments, ultimately improving the accuracy and reliability of optical measurement techniques.
Impact Journal Publication: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., Birk, A., Karemehmedovic, M., Lehmann, P., Reichelt, S., Leach, R. and Piano, S., 2025 Comparison of rigorous scattering models to accurately replicate the behaviour of scattered electromagnetic wave in optical surface metrology Journal of Computational Physics 521 113519. - Hooshmand, H., Pahl, T., de Groot, P. J., Lehmann, P., Pappas, A., Su, R., Leach, R. and Piano, S., 2024 Comparison of Fourier optics-based methods for modelling coherence scanning interferometry Optical Engineering 63 (4) 044102. Conference Publication: - Hooshmand, H., Pahl, T., de Groot, P. J., Pappas, A., Su, R., Leach, R. and Piano, S., 2023 Comparison of approximate methods for modelling coherence scanning interferometry SPIE Proceedings Volume 12619 Modelling Aspects in Optical Metrology IX 126190R (Munich, Germany). Invited talk: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., de Groot, P. J., Lehmann, P., Pappas, A., Birk, A., Leach, R. And Piano, S., 2023 Scattering methods for modelling optical surface topography measuring instruments 13th Seminar on Quantitative Microscopy and 9th Seminar on Nanoscale Calibration, Standards and Methods (Helsinki, Finland) - Invited paper.
Start Year 2021
 
Description Collaboration with INRIM on numerical modelling and systematic error analysis for the surface topography measuring instruments 
Organisation National Institute of Meteorological Research (INRIM)
Country Italy 
Sector Academic/University 
PI Contribution Our team at the university of Nottingham contributed to the collaboration within the TracOptic project, a Horizon Europe initiative focused on traceable industrial 3D roughness and dimensional measurement using optical 3D microscopy and optical distance sensors. Our primary role involved developing numerical models that predict the response for complex surface geometries and enabling their use in systematic error analysis and correction. We explored multiple approaches to model light diffraction and scattering, employing both approximate methods and rigorous solutions of Maxwell's equations. Additionally, we modelled a coherence scanning instrument using both approximate and rigorous scattering models to analyse systematic errors and enhance measurement accuracy.
Collaborator Contribution Our partners contributed by providing their advanced models for coherence scanning interferometry, as well as models for focus variation and confocal microscopy. They played a crucial role in validating and comparing results by implementing different modelling techniques and analysing the effects of various error sources. This collaborative effort ensured a comprehensive comparison between different virtual models and experimental data from real instruments, ultimately improving the accuracy and reliability of optical measurement techniques. INRIM played a crucial role in the selection of appropriate instrumentation and procedures for data evaluation and uncertainty estimation. They contributed by providing experimental measurement results, which were then compared with the simulation results generated by our virtual instruments. This comparison helped validate and refine the numerical models, ensuring better alignment between theoretical predictions and real-world measurements.
Impact Journal Publication: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., Birk, A., Karemehmedovic, M., Lehmann, P., Reichelt, S., Leach, R. and Piano, S., 2025 Comparison of rigorous scattering models to accurately replicate the behaviour of scattered electromagnetic wave in optical surface metrology Journal of Computational Physics 521 113519. - Hooshmand, H., Pahl, T., de Groot, P. J., Lehmann, P., Pappas, A., Su, R., Leach, R. and Piano, S., 2024 Comparison of Fourier optics-based methods for modelling coherence scanning interferometry Optical Engineering 63 (4) 044102. Conference Publication: - Hooshmand, H., Pahl, T., de Groot, P. J., Pappas, A., Su, R., Leach, R. and Piano, S., 2023 Comparison of approximate methods for modelling coherence scanning interferometry SPIE Proceedings Volume 12619 Modelling Aspects in Optical Metrology IX 126190R (Munich, Germany). Invited talk: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., de Groot, P. J., Lehmann, P., Pappas, A., Birk, A., Leach, R. And Piano, S., 2023 Scattering methods for modelling optical surface topography measuring instruments 13th Seminar on Quantitative Microscopy and 9th Seminar on Nanoscale Calibration, Standards and Methods (Helsinki, Finland) - Invited paper.
Start Year 2021
 
Description Collaboration with Institute of Applied Optics, University of Stuttgart 
Organisation University of Stuttgart
Department Institute of Applied Optics
Country Germany 
Sector Academic/University 
PI Contribution Collaboration with Dr. Liwei Fu, Institute of Applied Optics, University of Stuttgart was established. The aim is to use and to develop further their 3D BEM scattering code SpeckleSim. We would like to do comparison of Beckmann model and rigorous 3S BSM (our simulator) and SpeckleSim (Stutthart) simulators of coherence scanning interferometry. This will allow us to find the better option to model rigorously performance of CSI in 3D.
Collaborator Contribution Dr. Liwei Fu provided us with copy of her code SpeckleSim. This code was developed many years and works in two regimes: direct LU decomposition and iterative solver (multi-level fast multipole method (MLFMM)). She provided us with instructions and tutorials how to compile and to use it.
Impact Abstract for EOM25 SPIE Optical Metrology Symposium was submitted: Comparison of Beckmann model and rigorous 3S BSM and SpeckleSim simulators of coherence scanning interferometry. The plan is to write conference or journal paper. 3SBSM and SpeckleSim are different methods and there is a need to find out which one will be better to use for 3D rigorous simulations of coherence scanning interferometry. We would like to continue further our collaboration with Dr. Liwei Fu to use and to improve her code.
Start Year 2024
 
Description Collaboration with Institute of Applied Optics, University of Stuttgart, on numerical modelling and systematic error analysis for the surface topography measuring instruments 
Organisation University of Stuttgart
Country Germany 
Sector Academic/University 
PI Contribution Our team at the university of Nottingham contributed to the collaboration within the TracOptic project, a Horizon Europe initiative focused on traceable industrial 3D roughness and dimensional measurement using optical 3D microscopy and optical distance sensors. Our primary role involved developing numerical models that predict the response for complex surface geometries and enabling their use in systematic error analysis and correction. We explored multiple approaches to model light diffraction and scattering, employing both approximate methods and rigorous solutions of Maxwell's equations. Additionally, we modelled a coherence scanning instrument using both approximate and rigorous scattering models to analyse systematic errors and enhance measurement accuracy. As part of our collaboration with the University of Stuttgart, we worked on improving the 3D boundary element method originally developed by them. However, computing scattered light for multiple illuminations to generate CSI fringes using the MLFMM method proved infeasible due to extensive computational time requirements. Our work focused on finding alternative approaches to overcome this challenge and enhance computational efficiency. Collaboration with Dr. Liwei Fu, Institute of Applied Optics, University of Stuttgart was established. The aim is to use and to develop further their 3D BEM scattering code SpeckleSim. We would like to do comparison of Beckmann model and rigorous 3S BSM (our simulator) and SpeckleSim (Stutthart) simulators of coherence scanning interferometry. This will allow us to find the better option to model rigorously performance of CSI in 3D.
Collaborator Contribution Our partners contributed by providing their advanced models for coherence scanning interferometry, as well as models for focus variation and confocal microscopy. They played a crucial role in validating and comparing results by implementing different modeling techniques and analysing the effects of various error sources. This collaborative effort ensured a comprehensive comparison between different virtual models and experimental data from real instruments, ultimately improving the accuracy and reliability of optical measurement techniques. We are currently developing the 3D boundary element method originally developed by the University of Stuttgart. However, calculating scattered light for multiple illuminations to compute CSI fringes using the MLFMM method appears infeasible due to the extensive computational time required. Finding an alternative approach to overcome this challenge would be beneficial. Dr. Liwei Fu provided us with a copy of her code SpeckleSim. This code was developed many years and works in two regimes: direct LU decomposition and iterative solver (multi-level fast multipole method (MLFMM)). She provided us with instructions and tutorials on how to compile and to use it.
Impact Journal Publication: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., Birk, A., Karemehmedovic, M., Lehmann, P., Reichelt, S., Leach, R. and Piano, S., 2025 Comparison of rigorous scattering models to accurately replicate the behaviour of scattered electromagnetic wave in optical surface metrology Journal of Computational Physics 521 113519. - Hooshmand, H., Pahl, T., de Groot, P. J., Lehmann, P., Pappas, A., Su, R., Leach, R. and Piano, S., 2024 Comparison of Fourier optics-based methods for modelling coherence scanning interferometry Optical Engineering 63 (4) 044102. Conference Publication: - Hooshmand, H., Pahl, T., de Groot, P. J., Pappas, A., Su, R., Leach, R. and Piano, S., 2023 Comparison of approximate methods for modelling coherence scanning interferometry SPIE Proceedings Volume 12619 Modelling Aspects in Optical Metrology IX 126190R (Munich, Germany). Submitted: Abstract for EOM25 SPIE Optical Metrology Symposium was submitted: Comparison of Beckmann model and rigorous 3S BSM and SpeckleSim simulators of coherence scanning interferometry. The plan is to write a conference or journal paper. 3SBSM and SpeckleSim are different methods and there is a need to find out which one will be better to use for 3D rigorous simulations of coherence scanning interferometry. We would like to continue our collaboration with Dr. Liwei Fu to use and improve her code. Invited talk: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., de Groot, P. J., Lehmann, P., Pappas, A., Birk, A., Leach, R. And Piano, S., 2023 Scattering methods for modelling optical surface topography measuring instruments 13th Seminar on Quantitative Microscopy and 9th Seminar on Nanoscale Calibration, Standards and Methods (Helsinki, Finland) - Invited paper.
Start Year 2021
 
Description Collaboration with PTB on numerical modelling and systematic error analysis for the surface topography measuring instruments 
Organisation Physikalisch-Technische Bundesanstalt
Country Germany 
Sector Academic/University 
PI Contribution Our team at the university of Nottingham contributed to the collaboration within the TracOptic project, a Horizon Europe initiative focused on traceable industrial 3D roughness and dimensional measurement using optical 3D microscopy and optical distance sensors. Our primary role involved developing numerical models that predict the response for complex surface geometries and enabling their use in systematic error analysis and correction. We explored multiple approaches to model light diffraction and scattering, employing both approximate methods and rigorous solutions of Maxwell's equations. Additionally, we modelled a coherence scanning instrument using both approximate and rigorous scattering models to analyse systematic errors and enhance measurement accuracy.
Collaborator Contribution Our partners contributed by providing their own advanced models for coherence scanning interferometry, as well as models for focus variation and confocal microscopy. They played a crucial role in validating and comparing results by implementing different modeling techniques and analyzing the effects of various error sources. This collaborative effort ensured a comprehensive comparison between different virtual models and experimental data from real instruments, ultimately improving the accuracy and reliability of optical measurement techniques.
Impact Journal Publication: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., Birk, A., Karemehmedovic, M., Lehmann, P., Reichelt, S., Leach, R. and Piano, S., 2025 Comparison of rigorous scattering models to accurately replicate the behaviour of scattered electromagnetic wave in optical surface metrology Journal of Computational Physics 521 113519. - Hooshmand, H., Pahl, T., de Groot, P. J., Lehmann, P., Pappas, A., Su, R., Leach, R. and Piano, S., 2024 Comparison of Fourier optics-based methods for modelling coherence scanning interferometry Optical Engineering 63 (4) 044102. Conference Publication: - Hooshmand, H., Pahl, T., de Groot, P. J., Pappas, A., Su, R., Leach, R. and Piano, S., 2023 Comparison of approximate methods for modelling coherence scanning interferometry SPIE Proceedings Volume 12619 Modelling Aspects in Optical Metrology IX 126190R (Munich, Germany). Invited talk: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., de Groot, P. J., Lehmann, P., Pappas, A., Birk, A., Leach, R. And Piano, S., 2023 Scattering methods for modelling optical surface topography measuring instruments 13th Seminar on Quantitative Microscopy and 9th Seminar on Nanoscale Calibration, Standards and Methods (Helsinki, Finland) - Invited paper.
Start Year 2021
 
Description Collaboration with Prof. Han Hitjema at KL Leuven on uncertainty evaluation for surface topography measuring instruments 
Organisation University of Leuven
Country Belgium 
Sector Academic/University 
PI Contribution We collaborated with KU Leuven, working with Prof. Han Haitjema on uncertainty evaluation for surface topography measuring instruments. This collaboration focused on developing and refining methods to quantify measurement uncertainty in optical surface topography measuring instruments. By integrating metrological characteristics and virtual instrument approaches, we aimed to improve the reliability of measurement results and establish traceable uncertainty budgets for different topography measurement techniques.
Collaborator Contribution Prof. Han Haitjema, at KU Leuven, contributed expertise in uncertainty evaluation for surface topography measurement. His work focused on establishing robust uncertainty evaluation frameworks for different optical measurement techniques, helping to improve confidence in the accuracy and repeatability of surface topography measurements. His contribution supported the validation of measurement models and enhanced the reliability of uncertainty quantification in surface metrology.
Impact Based on this collaboration, one paper is submitted to a journal under review, and another draft has been prepared.
Start Year 2023
 
Description Collaboration with TUK on numerical modelling and systematic error analysis for the surface topography measuring instruments 
Organisation Technical University Kaiserslautern
Country Germany 
Sector Academic/University 
PI Contribution Our team at the university of Nottingham contributed to the collaboration within the TracOptic project, a Horizon Europe initiative focused on traceable industrial 3D roughness and dimensional measurement using optical 3D microscopy and optical distance sensors. Our primary role involved developing numerical models that predict the response for complex surface geometries and enabling their use in systematic error analysis and correction. We explored multiple approaches to model light diffraction and scattering, employing both approximate methods and rigorous solutions of Maxwell's equations. Additionally, we modelled a coherence scanning instrument using both approximate and rigorous scattering models to analyse systematic errors and enhance measurement accuracy.
Collaborator Contribution Our partners contributed by providing their own advanced models for coherence scanning interferometry, as well as models for focus variation and confocal microscopy. They played a crucial role in validating and comparing results by implementing different modelling techniques and analysing the effects of various error sources. This collaborative effort ensured a comprehensive comparison between different virtual models and experimental data from real instruments, ultimately improving the accuracy and reliability of optical measurement techniques.
Impact Journal Publication: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., Birk, A., Karemehmedovic, M., Lehmann, P., Reichelt, S., Leach, R. and Piano, S., 2025 Comparison of rigorous scattering models to accurately replicate the behaviour of scattered electromagnetic wave in optical surface metrology Journal of Computational Physics 521 113519. - Hooshmand, H., Pahl, T., de Groot, P. J., Lehmann, P., Pappas, A., Su, R., Leach, R. and Piano, S., 2024 Comparison of Fourier optics-based methods for modelling coherence scanning interferometry Optical Engineering 63 (4) 044102. Conference Publication: - Hooshmand, H., Pahl, T., de Groot, P. J., Pappas, A., Su, R., Leach, R. and Piano, S., 2023 Comparison of approximate methods for modelling coherence scanning interferometry SPIE Proceedings Volume 12619 Modelling Aspects in Optical Metrology IX 126190R (Munich, Germany). Invited talk: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., de Groot, P. J., Lehmann, P., Pappas, A., Birk, A., Leach, R. And Piano, S., 2023 Scattering methods for modelling optical surface topography measuring instruments 13th Seminar on Quantitative Microscopy and 9th Seminar on Nanoscale Calibration, Standards and Methods (Helsinki, Finland) - Invited paper.
Start Year 2021
 
Description Collaboration with University of Kassel on numerical modelling and systematic error analysis for the surface topography measuring instruments 
Organisation University of Kassel
Country Germany 
Sector Academic/University 
PI Contribution Our team at the university of Nottingham contributed to the collaboration within the TracOptic project, a Horizon Europe initiative focused on traceable industrial 3D roughness and dimensional measurement using optical 3D microscopy and optical distance sensors. Our primary role involved developing numerical models that predict the response for complex surface geometries and enabling their use in systematic error analysis and correction. We explored multiple approaches to model light diffraction and scattering, employing both approximate methods and rigorous solutions of Maxwell's equations. Additionally, we modelled a coherence scanning instrument using both approximate and rigorous scattering models to analyse systematic errors and enhance measurement accuracy.
Collaborator Contribution Our partners contributed by providing their own advanced models for coherence scanning interferometry, as well as models for focus variation and confocal microscopy. They played a crucial role in validating and comparing results by implementing different modeling techniques and analyzing the effects of various error sources. This collaborative effort ensured a comprehensive comparison between different virtual models and experimental data from real instruments, ultimately improving the accuracy and reliability of optical measurement techniques.
Impact Journal Publication: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., Birk, A., Karemehmedovic, M., Lehmann, P., Reichelt, S., Leach, R. and Piano, S., 2025 Comparison of rigorous scattering models to accurately replicate the behaviour of scattered electromagnetic wave in optical surface metrology Journal of Computational Physics 521 113519. - Hooshmand, H., Pahl, T., de Groot, P. J., Lehmann, P., Pappas, A., Su, R., Leach, R. and Piano, S., 2024 Comparison of Fourier optics-based methods for modelling coherence scanning interferometry Optical Engineering 63 (4) 044102. Conference Publication: - Hooshmand, H., Pahl, T., de Groot, P. J., Pappas, A., Su, R., Leach, R. and Piano, S., 2023 Comparison of approximate methods for modelling coherence scanning interferometry SPIE Proceedings Volume 12619 Modelling Aspects in Optical Metrology IX 126190R (Munich, Germany). Invited talk: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., de Groot, P. J., Lehmann, P., Pappas, A., Birk, A., Leach, R. And Piano, S., 2023 Scattering methods for modelling optical surface topography measuring instruments 13th Seminar on Quantitative Microscopy and 9th Seminar on Nanoscale Calibration, Standards and Methods (Helsinki, Finland) - Invited paper.
Start Year 2021
 
Description Collaboration with Zygo on numerical modelling and systematic error analysis for the surface topography measuring instruments 
Organisation Zygo Corporation
Country United Kingdom 
Sector Private 
PI Contribution Our team at the university of Nottingham contributed to the collaboration within the TracOptic project, a Horizon Europe initiative focused on traceable industrial 3D roughness and dimensional measurement using optical 3D microscopy and optical distance sensors. Our primary role involved developing numerical models that predict the response for complex surface geometries and enabling their use in systematic error analysis and correction. We explored multiple approaches to model light diffraction and scattering, employing both approximate methods and rigorous solutions of Maxwell's equations. Additionally, we modelled a coherence scanning instrument using both approximate and rigorous scattering models to analyse systematic errors and enhance measurement accuracy. Our collaboration with Zygo goes beyond this. We have regular informal discussions and meetings on improving coherence scanning interferometry (CSI) modeling, performing measurements with Zygo instruments, analysing influence factors contributing to measurement uncertainty, and exploring ways to enhance the overall quality of measurement results.
Collaborator Contribution Our partners contributed by providing their advanced models for coherence scanning interferometry, as well as models for focus variation and confocal microscopy. They played a crucial role in validating and comparing results by implementing different modelling techniques and analysing the effects of various error sources. This collaborative effort ensured a comprehensive comparison between different virtual models and experimental data from real instruments, ultimately improving the accuracy and reliability of optical measurement techniques. Additionally, Zygo has been actively involved in discussions on CSI modeling and measurement improvement. Their expertise in instrumentation and uncertainty analysis has contributed to refining the interpretation of measurement results, identifying key influence factors, and finding ways to improve measurement accuracy. The collaborative effort across all partners involved comparing results from different virtual models and experimental data from real instruments to enhance reliability and precision.
Impact Journal Publication: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., Birk, A., Karemehmedovic, M., Lehmann, P., Reichelt, S., Leach, R. and Piano, S., 2025 Comparison of rigorous scattering models to accurately replicate the behaviour of scattered electromagnetic wave in optical surface metrology Journal of Computational Physics 521 113519. - Hooshmand, H., Pahl, T., de Groot, P. J., Lehmann, P., Pappas, A., Su, R., Leach, R. and Piano, S., 2024 Comparison of Fourier optics-based methods for modelling coherence scanning interferometry Optical Engineering 63 (4) 044102. Conference Publication: - Hooshmand, H., Pahl, T., de Groot, P. J., Pappas, A., Su, R., Leach, R. and Piano, S., 2023 Comparison of approximate methods for modelling coherence scanning interferometry SPIE Proceedings Volume 12619 Modelling Aspects in Optical Metrology IX 126190R (Munich, Germany). Invited talk: - Hooshmand, H., Pahl, T., Hansen, P-E., Fu, L., de Groot, P. J., Lehmann, P., Pappas, A., Birk, A., Leach, R. And Piano, S., 2023 Scattering methods for modelling optical surface topography measuring instruments 13th Seminar on Quantitative Microscopy and 9th Seminar on Nanoscale Calibration, Standards and Methods (Helsinki, Finland) - Invited paper.
Start Year 2021
 
Description Derivation and evaluation of analytical transfer functions in closed form for axially symmetric 3D optical systems with Loughborough University 
Organisation Loughborough University
Country United Kingdom 
Sector Academic/University 
PI Contribution The contribution of Dr. Nikolaev from Nottingham University is analytical derivation of the transfer functions in closed forms and their numerical evaluations for forward and backward scattering optical instruments. The cases with different appodisation functions are considered.
Collaborator Contribution The contribution of Prof. Coupland from Loughborough University is in interpretation and verification of the analytical results obtained from Nottingham University. He widened the initial plan, which deals only with backscattered instruments and included consideration of forward scattering instruments. Different terms in analytical results obtained by Nottingham University were nicely explained by diagrams designed by Loughborough University.
Impact Manuscript "Analytical Transfer Characteristics of Axially Symmetric 3D Optical Systems" by N. Nikolaev J. Coupland is under preparation and will be submitted when finished.
Start Year 2024
 
Description NPL 
Organisation National Physical Laboratory
Department Environmental Measurement Group
Country United Kingdom 
Sector Academic/University 
PI Contribution Additive manufacturing of samples PhD student on design for merology for additive manufacturing EngD student on testing of surface texture software measurement standards PhD student on testing of materials properties for additive manufacturing
Collaborator Contribution Part funding for PhDs and EngD above Attendance on steering committee for Fellowship
Impact 83. Todhunter L, Leach R K, Lawes S D A, Blateyron F 2017 Comparison of Type F2 software measurement standards for profile surface texture parameters Meas. Sci. Technol. 28 065017. Smith I M, Harris P M, Todhunter L, Leach R K, Giusca C L, Jiang X, Scott P J 2017 Algorithms and software for areal surface texture function and feature parameters Meas. Sci. Technol. 28 105008. Todhunter L D, Leach R K, Lawes S D A, Blateyron F 2017 Industrial survey of ISO surface texture parameters CIRP J. Manufac. Sci. Technol. 19 84-92. Todhunter L, Leach R K, Lawes S D A 2017 An industrial survey on the use of surface texture parameters Proc. Met. & Props, Gothenburg, Sweden, Jun 166-167. Todhunter L, Leach R K, Lawes S D A, Blayteron F 2017 An analysis of Type F2 software measurement standards for profile texture parameters Proc. IMEKO, AMCTM XI, Glasgow, UK, Aug 11-12. Rivas Santos V M, Sims-Waterhouse D, Piano S, Maskery I, Leach R K 2017 Metrological design of calibration and benchmarking artefacts for an additive manufacturing system Proc. euspen/ASPE Dimensional Accuracy & Surface Finish in AM, Leuven, Belgium, Oct 24-27. Bitar I, Aboulkhair N, Leach R K 2017 The application of composite through-thickness assessment to additively manufactured parts SFF Symp. 2017, Austin, USA, Aug
Start Year 2015
 
Description Zygo 
Organisation Zygo Corporation
Country United Kingdom 
Sector Private 
PI Contribution 2 x PhD students working with Zygo instrumentation Research into instrument calibration and correction
Collaborator Contribution Supply of top-end coherence scanning interferometer and supervision of students Second instrument supplied (an upgrade)
Impact Su R, Wang Y, Coupland J M, Leach R K 2017 On tilt and curvature dependent errors and the calibration of coherence scanning interferometers Opt. Express 25 3297-3310. Gomez C, Thompson A, Su R, DiSciacca J, Lawes S, Leach R K 2017 Optimisation of surface measurement for metal additive manufacturing using coherence scanning interferometry Opt. Eng. 56 111714. Ekbert P, Su R, Leach R K 2017 High-precision lateral distortion measurement and correction in coherence scanning interferometry using an arbitrary surface Opt. Express 25 18703-18712. Liu M Y, Cheung C F, Cheng C H, Su R, Leach R K 2017 A Gaussian process based stitching method for high dynamic range optical measurement of precision surfaces Prec. Eng. 50 99-106. Su R, Thomas M, Leach R K, Coupland J M 2017 Effects of defocus on transfer function of coherence scanning interferometry Opt. Lett. 43 82-85.
Start Year 2016
 
Description AI + Engineering workshop in University of Nottingham 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Professional Practitioners
Results and Impact The AI+Engineering workshop brings together researchers from engineering and computer science to engage and bring about new ideas for research and collaboration. The workshop also provides hands-on tutorial sessions that teach students and researchers different AI techniques.
Year(s) Of Engagement Activity 2024
 
Description Euspen Special Interest Conference: Structured and Freefrom Surfaces, Nottingham, UK 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Oral presentation on 'Machine learning-based envelope extraction from downsampled coherence scanning interferometry signal data', followed by a discussion session on the topic.
Year(s) Of Engagement Activity 2024
URL https://www.euspen.eu/events/sic-structured-freeform-surfaces-september-2024/
 
Description ISMTII Conference, South Korea 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Oral: Virtual optical instrument for uncertainty evaluation in surface topography measurement
Oral: Determination of the influence of environmental vibration on the evaluation of measurement noise using a virtual instrument
Year(s) Of Engagement Activity 2023
URL https://www.ismtii2023.org/
 
Description International Conference on Metrology and Properties of Surfaces (Met&Props), Marrakech, Morocco 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Oral presntation on 'Effect of polarisation on the accuracy of surface topography measurement results in coherence scanning interferometry' followed by a discussion session on the topic.
Year(s) Of Engagement Activity 2024
URL https://metprops2024.org/
 
Description Manufacturing Metrology Seminar by Peter de Groot 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact The seminar discussed theoretical aspects of optics and modelling of optical instruments
Year(s) Of Engagement Activity 2024
 
Description Metrology Measurement Open Day in University of Nottingham 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Targeting business participants, professionals, academics, students, and the general public members interested in measurement and measurement systems, the event featured talks, discussions, tours and live demonstrations of a range of cutting-edge measurement systems. During this event, we introduced research goals and discussed challenges in modelling surface topography measurement. It provided a medium for networking and knowing what others are doing. We were introduced to other researchers that led to further engagements after the event.
Year(s) Of Engagement Activity 2024
URL https://www.mcddm.ac.uk/events/metrology-measurement-open-day-series-nottingham-14th-may-2024.aspx
 
Description Metrology Open Day - Coventry University 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact At Coventry, a series of presentations and a panel discussion with leading experts took place to discuss the future direction of Metrology and develop a roadmap for further academic and industrial collaboration.
Year(s) Of Engagement Activity 2024
URL https://www.mcddm.ac.uk/events/metrology-measurement-open-day-series-nottingham-14th-may-2024.aspx
 
Description Metrology Open Day - Loughborough University 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact At Loughborough, the results from recent projects on 3D machine vision & AI, multi-camera people tracking, and cobot-integrated measurement systems were presented with hands-on demos. The series of events concluded at Loughborough with the presentation of our future collaboration roadmap.
Year(s) Of Engagement Activity 2024
URL https://www.mcddm.ac.uk/events/metrology-measurement-open-day-series-nottingham-14th-may-2024.aspx
 
Description Metrology Open Day - University of Nottingham 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact At Nottingham, attendees received an overview of the MCDDM, its capabilities, and resources. Opportunities for short-term interventions with SMEs, as well as broader collaboration opportunities, were discussed. The keynote address was delivered by Eleanor Merson, Group Leader, Metrology Manufacturing at the National Physical Laboratory (NPL).
Year(s) Of Engagement Activity 2024
URL https://www.mcddm.ac.uk/events/metrology-measurement-open-day-series-nottingham-14th-may-2024.aspx
 
Description Nanoscale, Finland 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Oral: Scattering methods for modelling optical surface topography measurement instruments
Oral: Determination of the influence of environmental vibration on the evaluation of measurement noise using a virtual instrument
Year(s) Of Engagement Activity 2023
URL https://www.euramet.org/publications-media-centre/events/detail/event/nanoscale-2023
 
Description Optics seminar - metamaterials and optics for making metrology systems 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact I have attended this seminar as an audience as I am interested in the subject.
Year(s) Of Engagement Activity 2024
 
Description Participation Euspen Special Interest Conference: Structured & Freeform Surfaces 10th - 11th September 2024 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact At this conference the preliminary results from our work devoted to derivation of the 3D analytical transfer functions for CSI microscope in closed form are presented. Analytical solutions in closed form avoid heavy numerical calculation and offer easy way to calculate the response of the optical instruments. Our analysis is relevant to linear regime and covers axi-symmetric instrumentation with apodized apertures to include both aplanatic microscope objectives or uniform illumination (Herschel condition). The participants were interested from efficiency and accuracy of this method for a prediction of the performance of CSI instruments.
Title of presentation is: Understanding Coherence Scanning Interferometry: 3D Transfer Characteristics in a Closed Forms
N.I. Nikolaev1,2, S. Piano1, R.Leach1 and J.M. Coupland2
Year(s) Of Engagement Activity 2024
URL https://www.euspen.eu/events/sic-structured-freeform-surfaces-september-2024/
 
Description Physics of Waves and Optics Specialization (Rice University) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Course attended by: Isa Mohamed and Andrzej Frelek
Year(s) Of Engagement Activity 2023
 
Description Principles of Coordinate Metrology, Coventry University 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact A one day course attended by Helia Hooshmand, Ruidong Xue and Ahmet Koca
Year(s) Of Engagement Activity 2024
 
Description SPIE Optical Metrology conference, Germany 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Conference attended and oral paper presented: "Comparison of approximate methods for modelling coherence scanning interferometry"
Year(s) Of Engagement Activity 2023
URL https://spie.org/conferences-and-exhibitions/optical-metrology#_=_
 
Description SPIE Optics and Photonics conference, San Diego, US 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Invited talk on 'Evaluating approximate and rigorous scattering models in virtual coherence scanning interferometry for improved surface topography measurement', followed by a discussion session on the topic.
Year(s) Of Engagement Activity 2024
URL https://www.spiedigitallibrary.org/conference-proceedings-of-spie/13134/3027079/Evaluating-approxima...
 
Description Speaker at PMC Seminar 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact I have presented my work related to reviewing in-situ measurement methods in powder bed fusion.
Year(s) Of Engagement Activity 2024
 
Description euspen International Conference, Denmark 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Poster: Comparison of coherence scanning interferometry, focus variation and confocal microscopy for surface topography measurement
Poster: Uncertainty propagation of field areal surface texture parameters using the metrological characteristics approach
Year(s) Of Engagement Activity 2023
URL https://www.euspen.eu/events/22nd-international-conference-exhibition/#:~:text=30th%20May%20%E2%80%9...
 
Description euspen's 24th International Conference & Exhibition - Dublin 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Poster: Detecting microscale impurities on additive surfaces using light scattering
Year(s) Of Engagement Activity 2024
URL https://www.euspen.eu/events/24th-international-conference-exhibition-10th-14th-june-2024/?subid=24t...