In the optics and space industries, freeform optics has emerged as a key element. In addition to ultra-precision manufacturing and metrology techniques, advanced freeform optical designs have boosted human thinking, observations, and lifestyle. However, the development of ultraprecision freeform optics for transmissive and reflective modes becomes tedious when these modern components have to be integrated into optical, optomechanical, and optoelectronic systems for functional requirements. Factors like design scheme, size, positioning strategy, alignment, and functional testing have a direct influence on the cost of the project or freeform system building. Precision engineering aspects such as surface quality and form accuracy rely not only on the availability of state-of-the-art equipment and skilled operators, but also on an in-depth knowledge of freeform optics from conceptualization, design, manufacture, metrology, and functional testing. The main aim of the dissertation is to bridge the gap between optical design and optical fabrication by acquiring scientific knowledge and a fundamental understanding of freeform optics and its usage in various applications. The revolution of the freeform optical system using modern methods is presented in this Ph.D. thesis and is summed up by the following significant investigations:(a) Design approaches for freeform optical systems in reflective and transmissive modes. (b) Bridging the gap between design and manufacture of ultra-precision freeform optics. (c) Development of novel functional testing techniques for freeform optical systems. In contrast to rotational symmetrical optics or elements of conventional optical systems, the freeform optics do not specify an optical axis. The problems become tougher with disoriented systems, which provide additional challenges in product development of freeform optics. Therefore, novel design methodologies, fabrication techniques, positioning and alignment strategies, and functional testing must be established depending on particular type of freeform optics application. The research tasks comprise conducting case studies on the applications of freeform optical surfaces such as Head-up displays (HUDs) for automobiles and multi-facial freeform monolith (MFFM) for astronomical and space applications. To overcome challenges of surface imperfections via. mid-spatial frequency inaccuracies in complex freeform optics, a difference between the “design to manufacture” and “design to function” is defined. Fundamentals of parallel engineering or concurrent engineering are employed in each phase of the product development to build different freeform optical systems.
| Date of Award | 16 Dec 2024 |
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| Original language | English |
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| Sponsors | Engineering and Physical Sciences Research Council |
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| Supervisor | Wenhan Zeng (Main Supervisor), Jane Jiang (Co-Supervisor) & Wenbin Zhong (Co-Supervisor) |
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