Optical designers are encouraged to adopt aspheric and free-form surfaces into an increasing number of design spaces because of their improved performance. However, residual tooling marks from advanced aspheric fabrication techniques are difficult to remove. These marks, typically in the mid-spatial frequency (MSF) regime, give rise to structured image artifacts. Using a theory developed in previous publications, this paper applies the fundamentals of MSF modeling to demonstrate how MSF errors are evaluated and toleranced in an optical system. Examples of as-built components with MSF errors are analyzed using commercial optical design software.
Direct photolithographic deforming of hybrid glass films is used to fabricate optical structures. The structure is fabricated in polyethylene-oxide-acrylate modified hybrid glass films with (1) binary and gray-scale photomasks using a mercury UV-lamp exposure and (2) maskless UV-laser patterning. Fabrication of isolated lenslets, lens arrays, and gratings is presented, including the associated exposure patterns. The hybrid glass material yields light-induced deformation peak-to-valley (p.v.) heights up to 12.8 microm with mercury UV-lamp exposure and p.v. deformation heights up to 6.8 microm with 365-nm UV-laser exposure. The fabricated lenslets' surface data are presented as Zernike-polynomial fit coefficients. Material synthesis and processing-related aspects are examined to understand and control the material's deformation under exposure. The hybrid glass material exhibits a maximum spectral extinction coefficient of 1.6 x 10(-3) microm(-1) at wavelengths ranging from 450 to 2,200 nm and has a refractive index of 1.52 at 632.8 nm. The fabricated structures exhibit rms surface roughness between 1 and 5 nm.
The Gouy phase anomaly, well established for stigmatic beams, is validated here for astigmatic beams. We simulate the predicted Gouy phase anomaly near astigmatic foci using a beam propagation algorithm integrated within lens design software. We then compare computational results with experimental data acquired using a modified Mertz-Sagnac interferometer. Both in simulation and in experiment, results show that a π/2-phase change occurs as the beam passes through each of the astigmatic foci, experimentally validating results derived in a recent paper by Visser and Wolf [Opt. Commun. 283, 3371-3375 (2010)].
Aspheric and free-form surfaces are powerful surface forms that allow designers to achieve better performance with fewer lenses and smaller packages. Unlike spheres, these surfaces are fabricated with processes that leave a signature, or "structure," that is primarily in the mid-spatial-frequency region. These structured surface errors create ripples in the modulation transfer function (MTF) profile. Using Fourier techniques with generalized functions, the drop in MTF is derived and shown to exhibit a nonlinear relationship with the peak-to-valley height of the structured surface error.
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