Commercial Relevance of Freeform Optics. Mario Ledig Vice President Technology
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1 Commercial Relevance of Freeform Optics Mario Ledig Vice President Technology
2 Content Introduction and drivers for free form optics (technology, market) Market developments enabled by free forms Summary and outlook Qioptiq
3 How to approach commercial relevance.? Are the expectations too high, is it just a hype? Is it the solution for everything? Is there a systematic development behind? This is just an overview to commercial aspects. There many further applications.! Qioptiq
4 A few years ago only Qioptiq
5 Where are we today? Technology Drivers Machines Availability of CNC machines with universal features improved heavily (grinding, polishing, diamond turning) A number of sub aperture polishing technologies are available (MRF, fluid jet) Replication technologies progressed (plastics, glass) But: Applications demand for even more complex solutions Further progress is needed! Source : Optotech Source : Satisloh Source : Precitec Source : Moore Qioptiq
6 Where are we today? Technology Drivers Metrology 3D coordinate measuring machine well established and flexible but very time consuming interferometer with hologram adjustment very difficult, costly fringe reflection measurement quick, slopes directly measured, form error via integration (calibration!?) Wavefront sensor quick, slopes directly measured Need to progress continues as well! Source: Panasonic Source: Zeiss Source: 3D Shape Source: ZYGO LOT Source: Optocraft Qioptiq
7 Where are we today? Assembly technologies with free form components Discussion is often about machines and metrology Assembly technologies are often forgotten but play an even more important role because self referencing as for symmetric parts is not possible any more Two options - referencing to a fix point or edge of the component - adjustment according final system specifications Both methods show advantages and disadvantages Investigation within granted project FREE Again metrology of the finished system plays an important role Assembly technology needs to keep pace with capability to manufacture free form components! Qioptiq
8 Where are we today? Technology Drivers Optical Design Software xy Polynoms Z= ax+by+cx²+dy²+ex²y+fxy²... Zernike Polynoms Z m n m ( r, φ) R ( r) [ cos( mφ) + sin( mφ) ] = n B-Splines Nurbs Good coverage of free form design in commercial design software! Qioptiq
9 Market drivers There is not a typical market domain for free forms Application falls into a few main directions Systematic overview is a complex topic Solution demanding larger quantities playground for replication technologies (plastics, glass) free form design of replication tool Solution with classical imaging optics where free forms help to optimize performance and/or costs sub aperture grinding and polishing Diamond turning/milling of optical elements metal optics infrared optics Qioptiq
10 Content Introduction and drivers for free form optics (technology, market) Market developments enabled by free forms Summary and outlook Qioptiq
11 Market developments enabled by free forms General LED Lighting Market driver: Energy conservation and flexible application Street lighting, Buildings (inside, outside), Home applications, automotive applications etc. Efficient application possible only if part of a proper lamp design Substitution of lenses, scattering components and other parts of a lamp by a one reflector designed to the spatial and spectral properties of the LED radiation and the illumination task Properties of spatial emission of LED s request reflectors in free form design generally Lens for OSRAM Dragon source: LEDIL 3D free form lens source: OEC LED street lighting test New York City, source: inhabitat Qioptiq
12 Market developments enabled by free forms LED Lighting in Automotive Market driver: availability of strong white light LED s, governmental regulations, safety Markets: automotive lighting, security demands All kinds of headlight Topographic compensation Adaptive high beam, glare free headlight management Motorbike Indicator Light Audi R8 Headlight source: Audi 4 cushion shaped free form lenses for low beam, Cadillac Escalade Source: Hella Qioptiq
13 Market developments enabled by free forms Photovoltaics Market driver: Increase of efficiency of solar cells Concentrated Photovoltaic (CPV) as a method to increase solar cells efficiency Most efficient for multi junction solar cells Secondary optic directly on solar cell collects light focused by the primary optics (Fresnel lens) Secondary optics relaxes requirements on tracking accuracy to the sun Concentration factor approx. 500 Source: LPI Source: Concentrix Solar Source: LPI Qioptiq
14 Market developments enabled by free forms Individual Progressive Lenses Market driver: High level of presbyopia decease for age > 45 years Individual progressive lenses since a number of years High market acceptance due to strong benefit for wearers Manufacturing lot size: 1 Source: Zeiss Source: Rodenstock Qioptiq
15 Market developments enabled by free forms Head Up Displays in Automotive - Market Driver: Passenger Safety Content Management Standard Parameters Speed Drive Navigation Etc. System Messages Warning Status Augmented Reality Lane Steering information Etc. Night vision Source: TUM Source: BMW Cameras Rear view mirrors Rear view camera Inside mirror Panorama view 5 5 Qioptiq
16 Market developments enabled by free forms Head up displays with different size and technology Source: Qioptiq Qioptiq
17 Market developments enabled by free forms Automobile Rear View Mirror Blind spot problem due to limited field of view (FOV ) causes 4% of all crashes in US (1994, 225 fatalities) Spherical mirrors suffer from very high distortion Target: Eliminate blind spot but keep the image undistorted Solution by application of methods from differential geometry, numerical solution of a system of partial differential equations Saddle like surface as a low distortion solution Diamond turned mirror (Moore Nanotech 500FG, B-Con) with FOV 45 Method suitable for illumination tasks too Source: Andrew Hicks Drexel University, Philadelphia) Qioptiq
18 Market developments enabled by free forms Head Up Displays in Avionics - Market drivers: Safety Source: Qioptiq We have supplied over 17,000 Head-Up and Head-Down display optics for more than 30 aircraft types including Eurofighter, Tornado, A400M, A380 and Boeing 787 Qioptiq
19 Market developments enabled by free forms Source: Qioptiq Collimation behavior Binocular disparity - Convergence Binocular disparity - Dipvercene The values are shown at each position when moving the eye across the eye box Qioptiq
20 Market developments enabled by free forms Head Mounted displays Market drivers: Defence, Medical, Automotive, Sports, Leisure Near to eye projection Eye tracking Free form #1 DOE Source: IOF Aspheric base Free form #2 Source: IOF Two free forms + 1 DOE on an aspherical base surface Ultra precision milling Source: Qioptiq Qioptiq
21 Market developments enabled by free forms Defence: Wavefront coding Market: Night vision systems Phase mask produces an image which is insensitive to defocus but highly aberrated - image restored by image processing. 'Corrects' monochromatic, chromatic and thermal aberrations. Reduces tolerance sensitivity & may remove need for focus mechanism. Signal processing increases noise. Phase mask Detected Image Decoded Image Object Detector Post detection Processing IR objective with cubic phase mask Source: Qioptiq Qioptiq
22 Market developments enabled by free forms Manufacture using SPDT with slow tool servo Measurement Simulation Transmitted wavefront interferogram (10.6 µm) Latest hardware demonstrator freeform shape machined onto lens surface using fast tool servo Qioptiq
23 Market developments enabled by free forms Night Vision Camera View Conventional Wavefront coded Camera focused at approximately 20 m Qioptiq
24 Content Introduction and drivers for free form optics (technology, market) Market developments enabled by free forms Summary and outlook Qioptiq
25 Free form optics a decade down the road nothing totally new under sun But we have seen a strong progress within the last two years with - availability of machines and metrology - but a lot of new ideas and applications with demanding specifications keeps the pressure on machine builders A few applications with utmost potential are at the beginning of broader usage - general LED lighting - automobile lighting - other automobile applications (cameras, HUD) - concentrated PV? New concepts become available for optical systems with tight tolerances driving application in industries like medical technology, inspection, semiconductor etc Free form optics will become widely used and will drive technology development. But there is still a certain way to go until this will be a matter of course!! Qioptiq
26 Thank you.
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