Fermat meets PanDao: cost-efficient lens design

Abstract

Current optical design concepts and methods heavily rely on ray tracing and optimization algorithms. These methods often require extensive expertise, good intuition, and involve iterative trial-and-error workflows. We propose a novel approach that directly generates promising initial designs based on the application-and user-specific requirements and constraints. Our newly developed 'First Time Right' (FTR)-based design tool automatically calculates all optical surface coefficients to minimize image blurring across all aberration orders. Importantly, it also incorporates any imposed practical constraints, such as stop position, length, spacings, distortion, telecentricity or back focal length restrictions.To further enhance our methodology, we have combined our FTR-based Start Lens Generator with PanDao, a software that models fabrication chains based on provided design data. This integration aims to minimize both manufacturing costs and risks. We have evaluated and refined several real-world lens design examples, resulting in excellent alternative designs that maintain equivalent optical performance while typically achieving less stringent requirements for tolerances and significant reductions in overall production costs.