Universal dwell time optimization for deterministic optics fabrication.

Area of Science:

• Optical Engineering
• Precision Manufacturing
• Computational Metrology

Background:

• Computer-Controlled Optical Surfacing (CCOS) is crucial for precision optical fabrication.
• CCOS relies on accurate dwell time calculations, which are often ill-posed deconvolution problems.
• Existing methods struggle with non-negativity, residual minimization, efficiency, and computational cost.

Purpose of the Study:

• To introduce a novel Universal Dwell time Optimization (UDO) model for CCOS.
• To address the limitations of existing dwell time calculation methods.
• To achieve non-negative dwell times, minimize surface errors, and enhance process efficiency.

Main Methods:

• Employed matrix-based discretization of the convolutional polishing model for flexible dwell time calculations.
• Simplified inverse deconvolution into a forward scalar optimization for improved stability and efficiency.
• Utilized robust iterative refinement and a total dwell time reduction scheme.

Main Results:

• The UDO model successfully satisfies criteria for non-negative dwell times, minimized residuals, and reduced total dwell time.
• Simulations demonstrated the algorithm's superiority and general applicability across different CCOS processes.
• Real-world application on a synchrotron X-ray mirror using Ion Beam Figuring (IBF) showed significant reduction in surface residual (6.32 nm RMS to 0.19 nm RMS).

Conclusions:

• The proposed UDO model offers a universally applicable and efficient solution for CCOS dwell time optimization.
• UDO significantly improves surface accuracy and reduces processing time in precision optical fabrication.
• The model's effectiveness is validated through simulations and a practical application in Ion Beam Figuring.