One of the major developments in optics industry recently is the commercial manufacturing of freeform surfaces for optical mid- and high performance systems. The loss of limitation on rotational symmetry enables completely new optical design solutions – but causes completely new challenges for the manufacturer too. Adapting the serial production from radial-symmetric to freeform optics cannot be done just by the extension of machine capabilities and software for every process step. New solutions for conventional optics productions or completely new process chains are necessary.
The use of aspheres gives optical designers extended possibilities to develop lenses with higher speed, lower distortion
and better performance in ever smaller dimensions which would be nearly impossible to realize in a mere spherical design.
For the aspherical elements careful considerations on tolerancing, measurability and manufacturability are crucial
both for the as-built performance and for ensuring stable and cost-effective machining. Close collaboration between optical
design and the optical shop in charge is needed to ensure the best possible solution at minimum cost. High precision
aspheres for professional cine lenses with deviations from their best-fit-sphere in the range of millimeters are presented.
For them, figure errors down to 0.1 microns and slope errors down to 0.1' were achieved.
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