A Unified Model for Precision Optics to Predicting Performance Deviation of Precision Optics during Manufacturing

The quantitative prediction of optical performance remains a challenge in high-precision optomechanical systems due to the complex interaction between individual component quality and assembly-induced deviations. This paper proposes a unified calculation model for imaging accuracy that integrates manufacturing errors (as-fabricated surface variations) and assembly variations (adhesive-induced deformations) within a consistent tolerancing framework. Unlike conventional rigid-body tolerance analysis, our model treats the optical element as a compliant component where the final surface figure is the result of the initial manufacturing error superimposed with the elastoplastic deformation triggered by the bonding process. First, a theoretical model for optical surface is constructed considering both the processing error and assembly deformation. Then, surface error from processing and assembly state are considered to quantitatively predict the induced optical index, wavefront error. Finally, experiments are carried out through a controlled assembly experiment using an interferometer to measure both surface error and the transmitted wavefront error. The predicted RMS wavefront error (0.022λ and 0.021λ) shows reasonable agreement with the experimental measurements (0.015λ and 0.014λ), with differences within the estimated measurement uncertainty. The results demonstrate the effectiveness of the proposed model in predicting optical performance deviations considering both fabrication and assembly-induced surface errors.