SBIR Phase I: High Dynamic, Alignment Free Metrological Method for 3D Shape Measurement of Optical Surfaces Based on Polarization

该SBIR第一阶段研究计划旨在开发一种新的光学表面无干扰测量方法，具有高测量速度和高动态范围。下一代光学表面将需要大规模生产，具有高的球面形状和高数值孔径。制造这些光学元件是具有挑战性的，因为今天？有限的计量方法：接触传感器太慢而不能在过程中使用，而干涉仪和波前传感器具有小的有限动态范围并且需要仔细对准。研究的目的是证明基于偏振的方法的可行性，并评估其速度，动态范围，精度和对准的不敏感性。该方法结合了创新的偏振相机、特定照明和自动3D形状提取的新算法，将对用于各种应用的非球面光学元件的制造产生重大影响：用于太阳能发电的聚光光伏器件（CPV）、光学仪器、眼科镜片和消费电子产品（相机、手机）。该系统将允许大规模生产高质量的非球面透镜，并对每个制造部件进行单独检查。高数值孔径透镜也可以很容易地在加工过程中测量，这将大大提高生产率。这将转化为更快地部署更便宜，更高效的太阳能发电，更轻的光学系统和更好的矫正隐形眼镜。

This SBIR Phase I research proposal aims at developing a new alignment-free metrological method for optical surfaces with high measurement speed and high dynamic range. Next generation optical surfaces will need to be mass-produced with high departure from spherical shapes, and high numerical aperture. Manufacturing these optical components is challenging because of today?s limited metrology methods: contact sensors are too slow to be used in-process whereas interferometers and wave front sensors have a small limited dynamic range and require careful alignment. The research objective is to demonstrate the feasibility of a polarization based method and to evaluate its speed, dynamic range, accuracy, and insensitivity to alignment. The proposed approach combines an innovative polarization camera, a specific illumination, and a novel algorithm for automatic 3D shape extraction.The proposed metrology approach will have a major impact on the manufacturing of aspheric optical components used for various applications: concentrating photovoltaics (CPV) for solar power generation, optical instruments, ophthalmic lenses and consumer electronics (cameras, phones). The system would allow mass production of high quality aspheric lenses with individual inspection of each manufactured component. High numerical aperture lenses would also be measured easily in-process which will drastically increase productivity. This will translate into the faster deployment of cheaper, more efficient solar power production, lighter optical systems, and better corrected contact lenses.