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

该小型企业创新研究（SBIR）第一阶段项目旨在开发用于过程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式测量。该工具采用自适应工艺，以低于10微米的分辨率实现3D测量，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至关重要的作用，目前是新装配线、大批量制造、研究时间表和工具创造的限制因素。该工具本身将通过制造过程中的反馈来提高零件质量，从而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，预计在未来五年内将增长到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、实习生和专业特种机械师在小批量零件上实现复杂的精密公差。该项目的智力价值推动了精密光学投影的核心技术，该技术基于一种新型组件，可生成计算机定义的高分辨率投影光场，实现多功能性和高性能计量。可编程光场通过将实时测量信息投射到被检部件上，为用户提供直接反馈的机会。本研究的目的是通过实验评估几种设计排列的器件稳定性、视场、空间分辨率和效率来测量和优化该可编程器件的设计。其他目标包括评估器械的可制造性、可重复性和商业可行性。模拟表明，在40厘米的标称工作距离下，其功能包括60度角视场和亚10微米的投影光斑尺寸。进一步发展这一核心技术，结合商业上可用的组件，将能够创建一个紧凑，高精度，经济上可行的工具，为计量应用提供卓越的可靠性。该奖项反映了NSF的法定使命，并已被认为是值得通过使用基金会的智力价值和更广泛的影响审查标准进行评估的支持。

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.