Machining approach of freeform optics on infrared materials via ultra-precision turning

Optical freeform surfaces are of great advantage in excellent optical performance and integrated alignment features. It has wide applications in illumination, imaging and non-imaging, etc. Machining freeform surfaces on infrared (IR) materials with ultra-precision finish is difficult due to its brittle nature. Fast tool servo (FTS) assisted diamond turning is a powerful technique for the realization of freeform optics on brittle materials due to its features of high spindle speed and high cutting speed. However it has difficulties with large slope angles and large rise-and-falls in the sagittal direction. In order to overcome this defect, the balance of the machining quality on the freeform surface and the brittle nature in IR materials should be realized. This paper presents the design of a near-rotational freeform surface (NRFS) with a low non-rotational degree (NRD) to constraint the variation of traditional freeform optics to solve this issue. In NRFS, the separation of the surface results in a rotational part and a residual part denoted as a non-rotational surface (NRS). Machining NRFS on germanium is operated by FTS diamond turning. Characteristics of the surface indicate that the optical finish of the freeform surface has been achieved. The modulation transfer function (MTF) of the freeform optics shows a good agreement to the design expectation. Images of the final optical system confirm that the fabricating strategy is of high efficiency and high quality. Challenges and prospects are discussed to provide guidance of future work.