SBIR Phase I: Novel Holographic 3D Optical Metrology Tool for Precision Low-Volume Manufacturing

这个小型企业创新研究(SBIR)第一阶段项目是为了开发一种用于过程中质量控制的精密三维(3D)光学计量工具。该工具使用高分辨率、计算机定义的3D光场，在制造过程中对零件进行快速多点非接触测量。该工具使用自适应过程来实现分辨率低于10微米的3D测量，而价格仅为竞争技术的一小部分。小批量、高精度制造在全球经济中发挥着关键作用，目前是创建新装配线、大批量制造、研究时间表和工具制造的限制因素。该工具本身将通过在制造过程中通过反馈提高零件质量，使小型企业在硬件开发方面受益。表面检测系统已经占据了全球37亿美元的市场，预计未来五年将增长到53亿美元。这一具有战略影响力的创新旨在帮助小企业、学生、实习生和专业机械师在小批量零件上实现复杂、精密的公差。该项目的智力优势促进了精密光学投影的核心技术，基于一种新组件，该组件可生成计算机定义的高分辨率投影光场，从而实现多功能性和高性能测量。可编程光场通过将实时测量信息投射到被检查部件上，创造了直接用户反馈的机会。这项研究的目的是通过实验评估设备的稳定性、视场、空间分辨率和几种设计排列的效率，来测量和优化这种可编程设备的设计。其他目标包括评估该设备的可制造性、可重复性和商业可行性。模拟表明，它具有60度的视角，在标称工作距离为40厘米的情况下，投射光斑尺寸小于10微米。这项核心技术的进一步开发，与商业上可用的组件相结合，将能够创建一种紧凑、高精度、经济可行的工具，为计量应用提供非凡的可靠性。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

This Small Business Innovation Research (SBIR) Phase I project is for the development of a precision three-dimensional (3D) optical metrology tool for in-process quality control. The proposed tool uses a high-resolution, computer-defined 3D light field to perform rapid multipoint non-contact measurements on parts during the fabrication process. The tool uses an adaptive process to enable 3D metrology with sub-10-micron resolution, at a fraction of the price of competing technologies. Low-volume, high-precision manufacturing plays a critical role in the global economy and is currently a limiting factor in the creation of new assembly lines, larger volume manufacturing, research timelines, and tool creation. The tool itself will benefit small businesses in hardware development by improving part quality through feedback during the manufacturing process. Already, surface inspection systems account for a global $3.7 billion market which is projected to grow to $5.3 billion over the next five years. This strategically impactful innovation is aimed at assisting small businesses, students, trainees, and professional specialty machinists in achieving complex, precision tolerances on low-volume parts.The intellectual merit of this project advances core technology for precise optical projections, based on a novel component that generates a computer-defined high-resolution projected light field to enable both versatility and high-performance metrology. A programmable light field creates the opportunity for direct user feedback by projecting real-time measurement information onto the part under inspection. The objective of this study is to measure and optimize the design of this programmable device by experimentally evaluating the device stability, field of view, spatial resolution, and efficiency for several design permutations. Additional goals include evaluating the device for its manufacturability, repeatability, and commercial viability. Simulations suggest capabilities including a 60-degree angular field of view and sub-10-micron projection spot size at a nominal working distance of 40 centimeters. Further development of this core technology, when combined with commercially available components, will enable the creation of a compact, high-precision, economically viable tool that provides exceptional reliability for metrology applications.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.