The fabrication of microcomponents or microstructured surfaces with conventional manufacturing methods-such as turning, milling or drilling-imposes high demands on the machine behavior. The high requirements in terms of machine characteristics are currently met by only few ultraprecision machine tools. A broad range of materials such as, for example, non-ferrous metals or plastics can be machined, producing real three-dimensional structures with an optical surface quality
The system design of front-projection systems for free-form screens utilizing conventional single-aperture optical layouts always requires a trade-off between system complexity and achievable luminous output. This article presents novel slide pre-processing algorithms based on array projection technology that are able to resolve the design drawbacks for both free-form as well as strongly-inclined planar screen applications by breaking the common contradiction between system simplicity and flux. Starting from describing common design strategies and their drawbacks, the theoretical basics of the novel concept are investigated and applied to raytracing simulations. Experimental results are shown and evaluated regarding their optical performance.
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