Freeform optics have immense capabilities since they do not have the limitations of rotationally symmetric optics such as spheres and aspheres. However, the same qualities that make freeform optics so capable also make them challenging to produce cost-effectively. With advancements in optical manufacturing technology, freeform optics are becoming more prevalent in optical systems. While the latest solutions are necessary, the complexity of freeforms also requires experienced opticians that thoroughly understand the manufacturing process to produce these optics efficiently and within the required tolerances.
Vertex Optics has state-of-the-art grinding and polishing machines as well as optics professionals with decades of experience manufacturing freeform optics. For freeforms up to 150mm, rough and fine grinding of the surface is performed on the eSX 150 CNC optical grinding machine. For freeforms up to 300mm, the OptiSonic 550X is utilized for producing the ground surface. While the OptiSonic 550X has greater machine travel distance, both have the 5-axes of motion required for freeform optics grinding.
The engineers and technicians at Vertex harness the adaptability of the Triumph polishing machine, which also has 5-axes of motion and incorporates the Ultra Form Finishing sub-aperture polishing technology. The flexibility of UFF makes it capable of polishing a variety of freeform optical shapes to precision tolerances.
Measuring freeforms is the most critical part of the manufacturing process. Vertex Optics utilizes the Zeiss Accura CMM and Zygo Interferometers with CGHs to ensure the form error is properly corrected to a datum structure. Vertex has in-house software for error analysis to ensure its customers receive a high performing freeform component.
All these machines are capable of processing freeforms out of a variety of materials, including all optical glasses, crystals, and technical ceramics.