[2025] Kinematic interfaces for freeform optics for efficient manufacture, test, and system assembly

James H. Burge, Cormic Merle, Tyler Gross, and Aaron Clark “Kinematic interfaces for freeform optics for efficient manufacture, test, and system assembly”, Proc. SPIE 13599, Optomechanical Engineering 2025, 1359906 (18 September 2025)

Abstract:

Optical systems that use freeform optics have challenging alignment requirements because of the lack of symmetry and because the complex optical aberrations created by misalignment are not well compensated by other optics. Precision mechanics can define the position of the freeforms in an optical system using clean datum features that are accurately located with respect to optical surface. We present a metrology solution using computer generated holograms for simultaneously measuring optical surface form and mechanical location which allows the optics to be manufactured using predictive polishing or precision molding. The performance of this alignment method requires precise repeatability of the mechanical interfaces and the ability to accurately control mounting feature locations. We discuss the requirements and present several examples, showing interfaces that are used for optics manufacture, metrology, and integration. Additional elements are incorporated that take the shipping, launch, and operational loads.

Link to publication.