SBIR-STTR Award

Arizona Optical Systems has developed the breakthrough technology FORM (Flexible Optical Ray Metrology) that measures complex aspheric windows in transmission. {The FORM system for window metrology uses multiple CCD cameras that look through the window at modulated images on a digital display.} Powerful tomographic software and careful calibration are used to determine the surface irregularity of both surfaces of the window. Having performed the key demonstration of the FORM technique, we now propose to implement the technology to build a general purpose window metrology station that includes hardware, software, and procedures for system calibration and measurement of both surfaces of a wide range of window shapes. In Phase I we will create a prototype system and demonstrate measurement of an 8 0x9D steeply curved freeform window. In Phase II, we will build a robust system complete with stages and internal metrology to measure a range of windows up to 24 0x9D .

Benefit:
The program covered in this proposal will make significant advances in FORM technology, enabling snapshot 0x9D type measurement of large windows. AOS is currently developing a robust software engine that is used to calculate the surface distortions. The proposed program will enable the following significant advancements beyond those currently underway: Demonstration of a general purpose window metrology station. The system will enable a skilled technician to efficiently perform setup, calibration, measurement, and analysis tasks for a wide range of windows. Implementation of algorithm refinements to enable measurement of steeply curved windows, including 24 0x9D windows with 8 0x9D sag. These refinements have been identified and will be developed and demonstrated on this program. Advancement of system calibration to provide the same accuracy over 24 0x9D windows as the 4 0x9D window demonstrated. {We have recently invented a technique for in situ calibration uses a lithographed reference to calibrate the geometry errors in the display.} This technique will be refined and implemented full scale to achieve the highest possible accuracy for large window.

Keywords:
Tomography, Tomography, steep, Windows, Freeform, MANUFACTURE, conformal, Large, Measurement

Arizona Optical Systems has developed the breakthrough FORM (Flexible Optical Ray Metrology) that measures complex aspheric windows in transmission. Powerful tomographic software and careful calibration are used to determine the surface irregularity of both surfaces of the window. Having performed the key demonstration of the FORM technique, we now propose to implement the technology to build a general purpose window metrology station that includes hardware, software, and procedures for system calibration and measurement of both surfaces of a wide range of window shapes. In Phase I we created a prototype system and demonstrated measurements of an 8

Benefit:
A successful phase II effort will result in a complete system with all of the features and with the performance required for production measurement systems. This system would allow us to provide measurement services to window and optical manufacturers or other institutions that utilize optical systems. This system will also allow AOS to compete for window contracts, using our specialized metrology capabilities to provide the final processing feedback for high performance windows.

Keywords:
Freeform, window, Deflectometry, conformal, Measurement, MANUFACTURE, Tomography