This paper addresses the challenges and limitations involved in the measurement of steep freeform wavefront by using Shack-Hartmann Sensor (SHS). To estimate the slope errors, Zemax simulation tool is used to design a SHS setup including array of lenslets and detector plane with predefined specifications. In first step, error due to approximation of tilted plane wavefront over curved wavefront is simulated. Plane, tilted, curved and tilted-curved wavefronts are defined using appropriate ray source objects. The centroids of the focal spots of lenslets are calculated based on the detector data obtained by using ray tracing method, which is done by an in-plane scanning aperture for segmented local wavefronts sequentially.The scanning aperture is used to block rays from more than one lenslet array. Centroids from the focus spots are calculated and the slopes are estimated with respect to collimated reference wavefront for each ray trace process. Further, matrix of slope errors is used as an input for MATLAB routines for surface reconstruction and error estimation. Based on the simulation data, it is found that the assumption used in Shack-Hartmann wavefront measurement introduce residual errors. For example a 50 wave peak to valley input and 1.19 mm thick lenslet array can give up to 9 waves of residual form error. However, very thin lenslets can have very less residual error.The effect of shift of focal plane, tilted plane wavefront and curve wavefront during the reconstruction using SHS is reported.
An easily implementable illumination optical element enabling collection and redirection of multiple precollimated laser beams to be used as a laser spot illuminator (LSI) is proposed. Unlike the lenses, this element is free from any aberration and focusing/defocusing effects which may arise due to curved surfaces. The nonfocusing nature of beams reduces risk of the thermal instability at the target spot if compared with focused beam, especially for high brightness applications where multiple laser beams are used. Further, the illuminating spot is more uniform and pupil filling is higher which can help in the reduction of speckle contrast for imaging applications. In this research, we present two designs of LSI named biprism and sleek design, suitable for conventional grinding-polishing and molding methods of fabrication, respectively. It is shown that the proposed spot illuminator is suitable for conversion of lamp/LED-based projection engine design into a laser projector engine without any modification in its relay and imaging optics. Display performance parameters such as efficiency and uniformity across the modulator plane are reported and found acceptable for the projection engine designs using light tunnels as well as lenslet arrays for homogenization. Further, a prototype of a biprism laser illuminator for 2×4 laser arrays has been fabricated and evaluated to demonstrate its manufacturability.
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