Radical Measurement System for Lean Optics Manufacturing

Precision optics underpin the digital revolution, and other next-generation applications such as autonomous vehicles.

However, a fundamental bottleneck exists in the scalable manufacture of all precision optics across freeform, aspherical and spherical optical components, due to a lack of cost-effective technology to accurately measure 3-D forms of these surfaces for conformance and errors across the whole manufacturing process.

Visible wavelength laser interferometers are widely available, but are only suitable for quality assurance during the final fine-polishing stages. For pre-polishing of the component in rough-ground form (course abrasives), where large geometric errors can be unintentionally introduced, longer wavelength infrared (IR) interferometers exploit the reflectivity of rough surfaces to provide accurate 3-D profiles, with 20-times the dynamic range of visible interferometers.

However, very high system costs restrict adoption by all but the largest or high-value manufacturers (e.g. defence), with most limited to 1-D profilometry, which are too time-consuming to be effective, or forced to undertake polishing blind.

Corresponding re-works, rejection/wastage, throughput and piece-cost preclude participation of the majority of standard optics manufacturers from participating in the precision optics supply chain.

No existing technology cost-effectively overcomes these barriers or can operate at both visible and IR wavelengths.

In response, Optical Tools for Industry target a ground-breaking hybrid IR-visible interferometer using a new optical approach and corresponding configuration enabling radically reduced system costs.

Building on proof-of-concept work as well as both academic and industrial knowhow, this collaborative project with University of Huddersfield, Thin Metallic Films and Armstrong Optical will develop and validate this key enabling technology to prototype-level.

Stimulating significant economic and spill-over benefits, the project supports diversification and de-risking of SME supply chains for new enabling technologies addressing UK strategic targets (for example automotive, medical devices, pollution monitoring, and security/defence), as well as addressing the growing challenges of overseas supply chains through on-shoring.