Investigation into virtual manufacturing procedure for freeform optics

Successive approximation method is adopted in the design, manufacture, and test of freeform optics. This approach requires repeated trialanderror processes before a satisfactory result is achieved. Such repetitions are not only expensive, but also time consuming, and it becomes a bottleneck in the overall process flow. The virtual technology is an effective and fast way to solve this problem. An investigation into a virtual manufacturing and testing procedure (VMTP) for freeform optics is presented in this paper. The essential concepts about VMTP for optics ultraprecision machining（UPM） are put forward, including the construction of a VMTP model, the prototype structure of an optical system, and the virtual testing and sensitivity analysis of the imaging quality. The investigation indicates that this approach can accelerate the RD process, reduce the cost, enhance the manufacturability and improve the product quality.