Freeform Optics: Precision Solutions for Advanced Imaging

The optical axis of a freeform optical component is not symmetric. Optical designers find it intriguing because it allows for the correction of various aberrations with fewer optical surfaces and reduces weight and system compactness. Freeform optics has several applications in various fields of illumination, aerospace, biomedical engineering, renewable energy, optical imaging, automobiles, and more. It also offers significant benefits to system integrations.

A freeform optical component used in imaging systems enhances optical performance by removing optical aberrations. A freeform optical component used in illumination systems is designed to improve light energy efficiency by adjusting light intensity distribution.

A freeform reflector can also be used to make an automobile’s drive-side mirror, which offers a wide field of vision. Devices that need to be small, light, or have easy system integration require lenses and mirrors with intricate forms or freeform surfaces.

Get in touch now

Types of Optical Surfaces

Types of Optical Surfaces. Image Credit: Shanghai Optics Inc.

Understanding Freeform Optics

A freeform optical component is not symmetric in terms of translation or rotation. General XY polynomials often characterize freeform optical surfaces. Freeform optical components are sophisticated parts with more degrees of freedom than standard spherical optics.

A freeform optical surface has no constraints on its shape, whereas a conventional optical surface is rotationally symmetric. This has distinct advantages in boosting optical performance while lowering device size. However, freeform optical surfaces are more difficult to make; standard grinding, polishing, and precise turning cannot produce them.

Shanghai Optics Inc. fabricates freeform optical components using innovative technologies such as single-point diamond turning. Metals, plastics, germanium (Ge), calcium fluoride (CaF₂), magnesium fluoride (MgF₂), zinc selenide (ZnSe), zinc sulfide (ZnS), gallium arsenide (GaAs), silicon (Si), and other materials have been suggested as freeform lens/mirror substrates.

Freeform Optics ManufacturingPlay

Video Credit: Shanghai Optics Inc.

Get in touch now

Freeform Optics at Shanghai Optics

Fabricating and testing freeform optics require sophisticated manufacturing equipment and accurate metrology. Shanghai Optics uses advanced manufacturing techniques (including CNC machine tools and single-point diamond turning) to produce high-quality freeform optics and cutting-edge metrology (including surface profilers, interferometers, and computer-generated holograms) to verify the optical components.

The engineering team would be delighted to collaborate with users on the optical design, manufacture, and testing of optical components or systems, whether they comprise spherical optics, aspherical surfaces, or freeform optical surfaces.

Freeform Infrared Lens Design. Image Credit: Shanghai Optics Inc.