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    This study introduces a direct design method for cylindrical freeform imaging systems, incorporating manufacturing constraints for ultraprecise raster milling. The approach optimizes freeform mirrors for image quality while ensuring manufacturability for advanced optical systems.

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    Area of Science:

    • Optical Engineering
    • Manufacturing Technology

    Background:

    • Off-axis reflective imaging systems are crucial but often neglect manufacturing constraints in their design.
    • Ultraprecise fabrication methods like raster milling require specific design considerations for freeform optics.

    Purpose of the Study:

    • To propose a direct design method for cylindrical freeform imaging systems that integrates manufacturing constraints.
    • To facilitate the ultraprecise raster milling of freeform optical surfaces.

    Main Methods:

    • Constructing initial freeform shapes using feature data points based on constant optical path length.
    • Employing an iterative optimization process to adjust surface coefficients for image quality and manufacturability.
    • Ensuring freeform surfaces are distributed along a cylinder for raster milling compatibility.

    Main Results:

    • Validated a direct design method for off-axis three-mirror imaging systems (F/2.0, 100 mm EP, 4° × 4° FoV).
    • Demonstrated optimization for both image quality and deviation from a reference surface.
    • Guaranteed freeform surfaces suitable for a 150 mm radius cylinder for raster milling.

    Conclusions:

    • The proposed direct design method effectively incorporates manufacturing constraints into freeform imaging system design.
    • This method enables the fabrication of complex freeform optics using ultraprecise raster milling.
    • It offers a practical approach for designing manufacturable off-axis reflective imaging systems.