Lens Design Optimization/ Estimator Design 01 Description Document
UNIVERSITY OF ROCHESTER
Design Description
Document
Estimator/ Lens Design Optimization
Joe Centurelli, Natalie Pastuszka
Customer: Rick Plympton, Optimax Systems, Inc. Engineers: Joe Centurelli, Natalie Pastuszka, UR Insitute of Optics Advisor committee: Wayne Knox, Dan Brooks, Julie Bentley, UR Institute of Optics
Document Number: 01 Date: Revision Level: 5/1/2015 C
Authentication Block This is a computer generated document and the electronic master is the official revision. This paper copy is authenticated for the following purpose only:
The product vision is a compact, attachable microscope objective for a femtosecond micromachining system. This microscope objective will be part of a larger system that can write a GRIN structure into ophthalmic tissue. Several designs will be drafted to determine the effect of different performance specifications as a function of cost using Optimax Systems Inc.’s Estimator software.
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Contents Product Requirement Document
System Block Diagram
Optical Design
First Order Analysis
Estimator Software
Manufacturing Plan
Test Plan / Validation
Risk Assessment
Appendix
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Product Requirement Document (See digital document 1)
System Block Diagram 1) Microscope objective lens system
Optical Design
Overview: A microscope objective will be designed for a larger femtosecond micromachining system that uses focused laser pulses to inscribe refractive structures, namely GRIN structures, into ophthalmic tissue. The lens system will be water immersed and will need a working distance greater than 0.5mm before the coverslip that is placed on top of the cornea. The system will be diffraction limited 200-300µm behind the surface of the cornea.
Different designs will be drafted for three wavelengths: 400nm, 800nm, 1030nm. The microscope objectives at 400nm and 1030nm will be used with the cornea, while the 800nm will be used with hydrogels.
Figure 1. Basic schematic of microscope objective setup.
First Order Analysis and evaluation
Initial starting design was modeled after a general microscope objective design. The basic parameters were optimized using CODEV1 to yield a design that met the
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Lens Design Optimization/ Estimator Design 01 Description Document required specifications. The designs were then optimized for various performance specifications as a function of cost through an iterative process between the Estimator software and interactive tolerancing in CODE V. In this process, the biggest cost- driving tolerances were determined and loosed accordingly to decrease the total cost of the design while still meeting performance specifications, most importantly an RMS wavefront error less than or equal to 0.05waves.
400NM DESIGN
FINAL DESIGN
22:37:40
2.50 MM
400nm Scale: 10.00 26-Apr-15
Figure 2. Design of microscope objective at 400nm. Two aspheric surfaces were used, located on the first and fourth surfaces (first surface of each doublet).
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LENS LISTING
OPT 311 Base Parameters RDY THI RMD GLA CCY THC GLC > OBJ: INFINITY INFINITY 100 100 1: 7.68470 2.298588 SIO2_SCHOTT 0 0 ASP: K : 0.282377 KC : 0 CUF: 0.000000 CCF: 100 A :-.757164E-04 B :-.953128E-06 C :0.000000E+00 D :0.000000E+00 AC : 0 BC : 0 CC : 100 DC : 100
2: -12.57829 3.807102 SLAH51_OHARA 0 0 3: 1500.00000 0.200000 0 0 4: 7.68470 2.298588 SIO2_SCHOTT PIK PIK ASP: K : 0.282377 KC : PIK CUF: 0.000000 CCF: 100 A :-.757164E-04 B :-.953128E-06 C :0.000000E+00 D :0.000000E+00 AC : PIK BC : PIK CC : 100 DC : 100
5: -12.57829 3.807102 SLAH51_OHARA PIK PIK 6: 1500.00000 0.200000 PIK 0 STO: INFINITY 0.200000 100 0 8: 4.53441 2.000000 SIO2_SCHOTT 0 0 9: 16.89709 0.200000 0 0 10: 1.74372 1.500000 SIO2_SCHOTT 0 0 11: INFINITY 0.520000 'WATER1' 100 0 12: INFINITY 0.170000 NK5_SCHOTT 100 100 13: INFINITY 0.200000 'Cornea' 100 PIM IMG: INFINITY -0.000333 'Cornea' 100 0
SPECIFICATION DATA NA 0.70000 DIM MM WL 402.50 400.00 397.50 REF 2 WTW 1 10 1 XAN 0.00000 0.00000 0.00000 0.00000 0.00000 YAN 0.00000 0.04000 0.02000 0.07000 0.10000 WTF 1.00000 1.00000 1.00000 25.00000 100.00000 VUY 0.00000 -0.00075 -0.00037 -0.00130 - 0.00186 VLY 0.00000 0.00075 0.00037 0.00131 0.00188 POL N
APERTURE DATA/EDGE DEFINITIONS CA CIR S0 10.000000
PRIVATE CATALOG PWL 395.00 400.00 405.00 'WATER1' 1.344000 1.343600 1.343100
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PWL 400.00 395.00 405.00 'Cornea' 1.360000 1.360000 1.360000
REFRACTIVE INDICES GLASS CODE 402.50 400.00 397.50 SIO2_SCHOTT 1.469824 1.470094 1.470370 'WATER1' 1.343365 1.343600 1.343811 NK5_SCHOTT 1.537657 1.538026 1.538403 'Cornea' 1.360000 1.360000 1.360000 SLAH51_OHARA 1.817543 1.818342 1.819159
SOLVES PIM
PICKUPS PIK RDY S4 Z1 RDY S1 Z1 PIK RDY S5 Z1 RDY S2 Z1 PIK THI S4 Z1 THI S1 Z1 PIK THI S5 Z1 THI S2 Z1 PIK RDY S6 Z1 RDY S3 Z1 PIK K S4 Z1 K S1 Z1 PIK A S4 Z1 A S1 Z1 PIK B S4 Z1 B S1 Z1
INFINITE CONJUGATES EFL 6.7738 BFL 0.2000 FFL 8.6731 FNO 0.7143 IMG DIS 0.1997 OAL 17.2014 PARAXIAL IMAGE HT 0.0087 ANG 0.1000 ENTRANCE PUPIL DIA 6.9730 THI 13.8399 EXIT PUPIL DIA 6.7218 THI -6.3297
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TANGENTIAL 1.00 RELATIVE SAGITTAL FIELD HEIGHT 0.00025 0.00025 ( .1000 )O
-0.00025 -0.00025
0.70 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( .0700 )O
-0.00025 -0.00025
0.20 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( .0200 )O
-0.00025 -0.00025
0.40 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( .0400 )O
-0.00025 -0.00025
0.00 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( 0.000 )O
-0.00025 -0.00025
400nm 402.5000 NM 400.0000 NM RAY ABERRATIONS ( MILLIMETERS ) 397.5000 NM
23:46:07 26-Apr-15
Figure 3. Transverse ray plot for the design at 400nm.
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EVALUATION
FIRST ORDER THE SYSTEM IT IS DESIRABLE EVALUATION COMMENTS SPECIFICATIONS WILL HAVE THAT (ACTUAL VALUES)
APERTURE IMAGE NA= 0.7 IMAGE NA= 1.0 0.7 THE LAST SURFACE WILL BE IMMERSED IN WATER
FIELD ± 0.1 DEGREES ± 0.1 DEGREES
WAVELENGTHS 400 ± 3 NM 400 ± 3 NM 0.5 W TI:SAPPHIRE LASER SOURCE
PACKAGING/MANUFACTURING THE IT IS EVALUATION COMMENTS SYSTEM DESIRABLE SPECIFICATIONS (ACTUAL WILL HAVE THAT VALUES)
WORKING DISTANCE >0.5 MM 0.887 MM TO PREVENT CONTACT WITH CORNEAL TISSUE
FULL APERTURE >5MM, <12MM 6.78 MM
CLEAR APERTURE OF FIRST >10MM 6.1MM TO ACCOMMODATE BEAM WIDTH SURFACE
OVERALL LENGTH >5MM, <35MM 16.511MM LENGTH OF THE LENS ASSEMBLY FROM FIRST LENS SURFACE TO LAST LENS SURFACE
OBJECT COLLIMATED 0.5 W PULSED N/A FEMTOSECOND TI:SAPPHIRE LASER WITH APPROX. 10MM BEAM WIDTH
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FINAL SURFACE PLANO OR CONVEX PLANO FOR THE PREVENTION OF BUBBLES WHEN IMMERSED IN WATER
CEMENTED DOUBLETS NONE TWO FOR EASE OF MANUFACTURING
HEMISPHERICAL LENS SURFACES NONE ONE FOR EASE OF MANUFACTURING
MATERIAL THE SYSTEM IT IS DESIRABLE EVALUATION COMMENTS SPECIFICATIONS WILL HAVE THAT (ACTUAL VALUES)
GLASS TYPES USE OPTIMAX PREFERRED GLASSES SIO2 AND SLAH51 OPTIMAX SYSTEMS INC. PREFERRED GLASSES COLUMN (HTTP://WWW.OPTIMAXSI.COM/PREFERRED- GLASS/)
*ANOTHER GLASS TYPE MAY BE NEEDED TO CORRECT FOR CHROMATIC ABERRATIONS
SURFACE TYPES SPHERICAL ONLY 4 SPHERICAL, NO ASPHERES, GRINS, OR DOES DUE TO LIMITS OF OPTIMAX ESTIMATOR SOFTWARE 2 ASPHERES
MAXIMUM NUMBER <4 6 OF ELEMENTS
ANTI-REFLECTION V-COAT CENTERED AT 400NM N/A STANDARD OPTIMAX SYSTEMS INC. ANTI- COATING REFLECTION V- COAT
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PERFORMANCE THE SYSTEM IT IS DESIRABLE THAT EVALUATION COMMENTS SPECIFICATIONS WILL HAVE (ACTUAL VALUES)
TRANSMISSION 90% >90% 88.81%
RAY ANGLES OF <50 DEGREES <40 DEGREES MAX AOI: 31.679 NEEDED TO SIMPLIFY THE COATING INCIDENCE AND DESIGN REFRACTION ON ALL MAX AOR: 31.679 COATED SURFACES
WAVE FRONT ERROR LESS THAN 0.05 WAVES 0.02188
DIFFRACTION LIMITED 200µM BEHIND THE SURFACE OF THE N/A CORNEA TO 300µM BEHIND THE SURFACE OF THE CORNEA
VIGNETTING NONE NONE TO INCREASE TRANSMISSION
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800NM DESIGN
FINAL DESIGN
23:08:06
2.27 MM
800nm Scale: 11.00 26-Apr-15
Figure 4. Design of microscope objective at 800nm. All elements are spherical.
LENS LISTING
800nm RDY THI RMD GLA CCY THC GLC > OBJ: INFINITY INFINITY 100 100 1: 10.81065 2.250000 SIO2_SCHOTT PIK PIK CEM: CIN: CTH: 0.0000 2: -18.64693 2.250000 STIH53_OHARA PIK PIK 3: 1500.00000 0.200000 PIK 0 4: 10.81065 2.250000 SIO2_SCHOTT 0 0 CEM: CIN: CTH: 0.0000
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5: -18.64693 2.250000 STIH53_OHARA 0 0 6: 1500.00000 0.200000 0 0 STO: INFINITY 0.200000 100 0 8: 5.48264 2.250000 SIO2_SCHOTT 0 0 CEM: CIN: CTH: 0.0000 9: 19.33180 0.200000 0 0 10: 3.00000 3.629633 SIO2_SCHOTT 0 0 CEM: CIN: CTH: 0.0000 11: INFINITY 0.550000 'water8' 100 0 12: INFINITY 0.170000 NK5_SCHOTT 100 100 13: INFINITY 0.200000 'Hydrogel' 100 PIM IMG: INFINITY -0.000709 'Hydrogel' 100 0
SPECIFICATION DATA NA 0.70000 DIM MM WL 804.00 802.00 800.00 798.00 796.00 REF 3 WTW 1 2 4 2 1 XAN 0.00000 0.00000 0.00000 YAN 0.00000 0.07000 0.10000 WTF 1.00000 1.00000 1.00000 VUY 0.00000 -0.00033 -0.00048 VLY 0.00000 0.00033 0.00048 POL N
APERTURE DATA/EDGE DEFINITIONS CA CIR S0 10.000000 CIR S1 EDG 5.000000 CIR S2 EDG 5.000000 CIR S3 EDG 5.000000 CIR S4 EDG 5.000000 CIR S5 EDG 5.000000 CIR S6 EDG 5.000000
PRIVATE CATALOG PWL 395.00 400.00 405.00 'WATER1' 1.344000 1.343600 1.343100
PWL 400.00 395.00 405.00 'Cornea' 1.360000 1.360000 1.360000
PWL 800.00 802.50 797.50 'water8' 1.328100 1.328100 1.328200 'hydrogel' 1.380000 1.380000 1.380100
PWL 804.00 800.00 796.00 'Hydrogel' 1.460000 1.460000 1.460000
REFRACTIVE INDICES GLASS CODE 804.00 802.00 800.00 798.00 796.00 SIO2_SCHOTT 1.453226 1.453260 1.453294 1.453329 1.453364 NK5_SCHOTT 1.515989 1.516030 1.516071 1.516112 1.516153 STIH53_OHARA 1.823146 1.823279 1.823413 1.823548 1.823684 'water8' 1.328121 1.328096 1.328100 1.328166 1.328390 'Hydrogel' 1.460000 1.460000 1.460000 1.460000 1.460000
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SOLVES PIM
PICKUPS PIK RDY S1 Z1 RDY S4 Z1 PIK RDY S2 Z1 RDY S5 Z1 PIK RDY S3 Z1 RDY S6 Z1 PIK THI S1 Z1 THI S4 Z1 PIK THI S2 Z1 THI S5 Z1
INFINITE CONJUGATES EFL 8.3288 BFL 0.2000 FFL 2.2503 FNO 0.7143 IMG DIS 0.1993 OAL 16.3996 PARAXIAL IMAGE HT 0.0100 ANG 0.1000 ENTRANCE PUPIL DIA 7.9865 THI 7.8694 EXIT PUPIL DIA 8.1081 THI -8.2556
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TANGENTIAL 1.00 RELATIVE SAGITTAL FIELD HEIGHT 0.00025 O 0.00025 ( .1000 )
-0.00025 -0.00025
0.70 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( .0700 )O
-0.00025 -0.00025
0.00 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( 0.000 )O
F F i g F -0.00025 -0.00025 i 800nm 804.0000 NM g 802.0000 NM u 800.0000 NM RAY ABERRATIONS ( MILLIMETERS ) 798.0000 NM r 796.0000 NM 23:49:17 26-Apr-15 e
5. Transverse ray plot for the design at 800nm.
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EVALUATION
FIRST ORDER THE SYSTEM IT IS DESIRABLE EVALUATION COMMENTS SPECIFICATIONS WILL HAVE THAT (ACTUAL VALUES)
APERTURE IMAGE NA= 0.7 IMAGE NA= 1.0 0.7- 0.8 THE LAST SURFACE WILL BE IMMERSED IN WATER
FIELD ± 0.1 DEGREES ± 0.1 DEGREES
WAVELENGTHS 800 ± 3 NM 800 ± 3 NM 0.5 W TI:SAPPHIRE LASER SOURCE
PACKAGING/MANUFACTURING THE IT IS EVALUATION COMMENTS SYSTEM DESIRABLE SPECIFICATIONS (ACTUAL WILL HAVE THAT VALUES)
WORKING DISTANCE >0.5 MM 0.919 MM TO PREVENT CONTACT WITH CORNEAL TISSUE
FULL APERTURE >5MM, <12MM 8.89 MM
CLEAR APERTURE OF FIRST >10MM 8.0MM TO ACCOMMODATE BEAM WIDTH SURFACE
OVERALL LENGTH >5MM, <35MM 15.680MM LENGTH OF THE LENS ASSEMBLY FROM FIRST LENS SURFACE TO LAST LENS SURFACE
OBJECT COLLIMATED 0.5 W PULSED N/A FEMTOSECOND TI:SAPPHIRE LASER WITH APPROX. 10MM BEAM WIDTH
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FINAL SURFACE PLANO OR CONVEX PLANO FOR THE PREVENTION OF BUBBLES WHEN IMMERSED IN WATER
CEMENTED DOUBLETS NONE TWO FOR EASE OF MANUFACTURING
HEMISPHERICAL LENS SURFACES NONE ONE FOR EASE OF MANUFACTURING
MATERIAL THE SYSTEM IT IS DESIRABLE EVALUATION COMMENTS SPECIFICATIONS WILL HAVE THAT (ACTUAL VALUES)
GLASS TYPES USE OPTIMAX PREFERRED SIO2 AND STIH53 OPTIMAX SYSTEMS INC. PREFERRED GLASSES GLASSES COLUMN (HTTP://WWW.OPTIMAXSI.COM/PREFERRED- GLASS/)
*ANOTHER GLASS TYPE MAY BE NEEDED TO CORRECT FOR CHROMATIC ABERRATIONS
SURFACE TYPES SPHERICAL ONLY SPHERICAL NO ASPHERES, GRINS, OR DOES DUE TO LIMITS OF OPTIMAX ESTIMATOR SOFTWARE
MAXIMUM <4 6 NUMBER OF ELEMENTS
ANTI-REFLECTION V-COAT CENTERED AT 400NM N/A STANDARD OPTIMAX SYSTEMS INC. ANTI- COATING REFLECTION V- COAT
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PERFORMANCE THE SYSTEM IT IS DESIRABLE EVALUATION COMMENTS SPECIFICATIONS WILL HAVE THAT (ACTUAL VALUES)
TRANSMISSION 90% >90% 82.86%
RAY ANGLES OF <50 DEGREES <40 DEGREES MAX AOI: 32.227 NEEDED TO SIMPLIFY THE COATING INCIDENCE AND DESIGN MAX AOR: REFRACTION ON ALL 32.227 COATED SURFACES
WAVE FRONT ERROR LESS THAN 0.05 WAVES 0.00932
DIFFRACTION LIMITED 200µM BEHIND THE SURFACE OF THE N/A CORNEA TO 300µM BEHIND THE SURFACE OF THE CORNEA
VIGNETTING NONE NONE TO INCREASE TRANSMISSION
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1030NM DESIGN
FINAL DESIGN
23:46:53
2.50 MM
1030nm Scale: 10.00 NP 26-Apr-15 Figure 6. Design of microscope objective at 1030nm. All are spherical elements.
LENS LISTING
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1030 test RDY THI RMD GLA CCY THC GLC > OBJ: INFINITY INFINITY 100 100 1: 13.12105 2.316524 SBAL14_OHARA 0 0 2: -12.72111 2.166945 TIH6_OHARA 0 0 3: 106.03015 0.400000 0 0 4: 13.12105 2.316524 SBAL14_OHARA PIK PIK PIK 5: -12.72111 2.166945 TIH6_OHARA PIK PIK 6: 106.03015 0.200000 PIK 0 STO: INFINITY 0.200000 100 0 8: 7.23807 3.633176 SBAL14_OHARA 0 0 9: INFINITY 0.220000 100 0 10: 3.01000 3.010000 SIO2_SCHOTT 0 0 CEM: CIN: CTH: 0.0000 11: INFINITY 0.779101 'Water' 100 0 12: INFINITY 0.170000 NK5_SCHOTT 100 100 13: INFINITY 0.199997 'CorneaS' 100 PIM IMG: INFINITY -0.000288 'CorneaS' 100 0
SPECIFICATION DATA NA 0.70000 DIM MM WL 1034.00 1032.00 1030.00 1028.00 1026.00 REF 3 WTW 1 2 4 2 1 INI NP XAN 0.00000 0.00000 0.00000 0.00000 0.00000 YAN 0.00000 0.05000 0.07070 0.08660 0.10000 WTF 1.00000 1.00000 1.00000 1.00000 1.00000 VUY 0.00000 -0.00015 -0.00021 -0.00026 -0.00029 VLY 0.00000 0.00015 0.00021 0.00026 0.00029 POL N
APERTURE DATA/EDGE DEFINITIONS CA CIR S0 10.000000 CIR S4 4.000000 CIR S5 4.056300 CIR S6 3.885300
PRIVATE CATALOG PWL 395.00 400.00 405.00 'WATER1' 1.344000 1.343600 1.343100
PWL 400.00 395.00 405.00
PWL 800.00 802.50 797.50 'water8' 1.328100 1.328100 1.328200 'hydrogel' 1.380000 1.380000 1.380100
PWL 804.00 800.00 796.00 'Hydrogel' 1.460000 1.460000 1.460000
PWL 1030.00 1035.00 1025.00 'Water' 1.324730 1.324650 1.324800
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PWL 1025.00 1030.00 1035.00 'Cornea' 1.360000 1.360000 1.360000
PWL 550.00 'CorneaS' Constants of Glass Mfrs Sellmeier Dispersion Formula B1 0.544000E+00 C1 0.540000E-02 B2 0.315179E+00 C2 0.180179E-01 B3 0.101046E+01 C3 0.603560E+03 B4 0.000000E+00 C4 0.000000E+00 B5 0.000000E+00 C5 0.000000E+00 B6 0.000000E+00 C6 0.000000E+00
REFRACTIVE INDICES GLASS CODE 1034.00 1032.00 1030.00 1028.00 1026.00 SBAL14_OHARA 1.557316 1.557345 1.557375 1.557404 1.557433 TIH6_OHARA 1.774321 1.774384 1.774447 1.774511 1.774575 SIO2_SCHOTT 1.449973 1.449998 1.450022 1.450047 1.450072 'Water' 1.324667 1.324699 1.324730 1.324759 1.324787 NK5_SCHOTT 1.512305 1.512331 1.512358 1.512384 1.512411 'CorneaS' 1.365851 1.365866 1.365880 1.365894 1.365909
SOLVES PIM
PICKUPS PIK RDY S4 Z1 RDY S1 Z1 PIK THI S4 Z1 THI S1 Z1 PIK RDY S5 Z1 RDY S2 Z1 PIK THI S5 Z1 THI S2 Z1 PIK RDY S6 Z1 RDY S3 Z1 PIK GL1 S4 Z1 GL1 S1 Z1
INFINITE CONJUGATES EFL 8.0378 BFL 0.2000 FFL 3.3654 FNO 0.7143 IMG DIS 0.1997 OAL 17.5792 PARAXIAL IMAGE HT 0.0103 01Rev APage | 20
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ANG 0.1000 ENTRANCE PUPIL DIA 8.2386 THI 7.9158 EXIT PUPIL DIA 10.6544 THI -10.1947
TANGENTIAL 1.00 RELATIVE SAGITTAL FIELD HEIGHT 0.00025 0.00025 ( .1000 )O
-0.00025 -0.00025
0.87 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( .0866 )O
-0.00025 -0.00025
0.71 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( .0707 )O
-0.00025 -0.00025
0.50 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( .0500 )O
-0.00025 -0.00025
0.00 RELATIVE FIELD HEIGHT 0.00025 0.00025 ( 0.000 )O
-0.00025 -0.00025
1030nm 1034.0000 NM 1032.0000 NM 1030.0000 NM RAY ABERRATIONS ( MILLIMETERS ) 1028.0000 NM 1026.0000 NM 23:47:56 NP 26-Apr-15
i Figure 7. Transverse ray plot for the design at 800nm.
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EVALUATION
First Order The System Will It is Desirable Evaluation Comments Specifications Have That (actual values)
Aperture Image NA= 0.7 Image NA= 1.0 0.7- 0.9 The last surface will be immersed in water
Field ± 0.1 degrees ± 0.1 degrees
Wavelengths 1030 ± 4 nm 1030 ± 3 nm Fiber Laser Source
Packaging/Manufacturing The System It is Desirable Evaluation Comments Will Have That Specifications (actual values)
Working Distance >0.5 mm 1.149 mm To prevent contact with corneal tissue
Full Aperture >5mm, <12mm 9.17 mm
Clear Aperture of first surface >10mm 8.26mm To accommodate beam width
Overall Length >5mm, <35mm 16.63mm Length of the lens Assembly from First Lens Surface to Last Lens Surface
Object Collimated 0.5 W Pulsed N/A
Femtosecond Ti:Sapphire Laser with approx. 10mm beam width
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Final surface Plano or Convex Plano For the prevention of bubbles when immersed in water
Cemented Doublets None Two For ease of manufacturing
Hemispherical Lens Surfaces None One For ease of manufacturing
Material The System It is Desirable Evaluation Comments Specifications Will Have That (actual values)
Glass Types Use Optimax preferred glasses SBAL14 and TIH6 Optimax Systems Inc. preferred glasses column (http://www.optimaxsi.com/preferred- glass/)
*another glass type may be needed to correct for chromatic aberrations
Surface Types Spherical Only Spherical No Aspheres, GRINs, or DOEs due to limits of Optimax Estimator Software
Maximum <4 6 Number of Elements
Anti-Reflection V-coat centered at 400nm N/A Standard Optimax Systems Inc. anti- Coating reflection V- coat
Performance The System It is Desirable That Evaluation Comments Specifications Will Have (actual values)
Transmission 90% >90% 90.08% * Transmission 77.01% if no coatings on SBAL14.
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Ray angles of <50 Degrees <40 Degrees Max AOI: 31.90 Needed to Simplify the Coating incidence and Design refraction on all Max AOR: 31.90 coated surfaces
Wave front error Less than 0.05 Waves 0.00315
Diffraction Limited 200µm behind the surface of the N/A cornea to 300µm behind the surface of the cornea
Vignetting None None To increase transmission
Estimator Software The designs will be optimized for price as a function of:
- Numerical aperture - Different design forms - Tolerances - Quantity - Wavelength By inputting each optical element into the Estimator software4, we will compile data to analyze how each parameter affects the ultimate budget.
List of considered tolerances: Radius of Curvature Center thickness Surface Roughness Test Plate Refractive Index V- number Fit Irregularity Wedge Diameter Roll Diameter Cosmetics Decenter Clear Aperture
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Relative Price of Tolerance Level
90%
80% CT (mm)
70% Wedge (mm) 60% Radius (fringes) 50% Irregularity (fringes) 40% Cosmetics 30%
Percent increase in cost in increase Percent 20%
10%
0% Commerical Precision High Precision Tolerance Level
Figure 8. Relative Price based on tolerance level5. For each of the three tolerance levels, the weight of specific tolerances on price were analyzed. Irregularity had the greatest influence on price with tolerance level, followed by center thickness, cosmetics, and radius. Wedge did not have a strong impact on price across the tolerance levels.
Relative Price vs. Irregularity Tolerance
100% NA 0.8 Miniscus 80% NA 0.75 Miniscus 60% NA 0.7 Miniscus 40% NA 0.8 Bi-convex 20% NA 0.75 Bi-convex 0%
Percent increase cost in increase Percent NA 0.7 Bi-convex 0.20.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 NA 0.8 Bi-concave Irregularity Tolerance
Figure 9. Further analysis of price as a function of irregularity. As the irregularity tolerance increases, the relative price of the optic decreases. This trend is independent of numerical aperture and element.
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Relative Price vs. Numerical Aperture
16%
14% 12% 10% 8% 6% 4%
2% Percent increase cost in increase Percent 0% 0.7 0.75 0.8 Numerical Aperture
Figure 10. Price as a function of numerical aperture. The relative price increased as numerical aperture increased. This relative trend was observed across all wavelength designs.
Relative Price Vs Center Thickness Tolerance 50.00%
High NA 0.8 Miniscus Precision 40.00% NA 0.75 Miniscus NA 0.7 Miniscus NA 0.8 Bi-convex 30.00% NA 0.75 Bi-convex NA 0.7 Bi-convex NA 0.8 Bi-concave Preci 20.00% NA 0.75 Bi-concave NA 0.7 Bi-concave
Percent increasePercent cost in Average 10.00% Comm ercial 0.00% 0 0.025 0.05 0.075 0.1 0.125 0.15 0.175 0.2 Tolerance
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Relative Price Vs Radius Tolerance 20.00%
18.00%
16.00% 14.00% 12.00% 10.00% 8.00% 6.00%
4.00% Percent increasePercent cost in 2.00% 0.00% 1 3 5 Radius tolerance (lens units)
NA 0.8 Miniscus NA 0.75 Miniscus NA 0.7 Miniscus NA 0.8 Bi-convex NA 0.75 Bi-convex NA 0.7 Bi-convex NA 0.8 Bi-concave NA 0.75 Bi-concave NA 0.7 Bi-concave Average
Lowest price for each wavelength
400nm 800nm 1030nm
$19,560 $5,250 $5,840
To summarize these results, in the process of using the Estimator software in conjunction with interactive tolerancing in CODE V, the biggest cost- driving tolerance was determined to be irregularity, followed by center thickness, cosmetics, and radius of curvature. These tolerances were loosened as much as possible with the goal of reducing the total cost of the optical system without compromising the performance of the microscope objectives. With this process and a few other cost saving tricks, we have been able to reduce the cost of a system by nearly a factor of four.
Among other observations, price increased with numerical aperture due to the requirement for the tolerances to be tightened to still meet a probability of 80% successful manufacturability. When considering the purely spherical designs and analyzing price as a function of wavelength for longer wavelengths, there is no 01Rev APage | 27
Lens Design Optimization/ Estimator Design 01 Description Document evident conclusion that the price is affected by wavelength. However, it was evident that the UV (400nm) system required aspheric elements to be able to meet specifications, and thus increased the total cost per unit due to the difficulty of manufacturability of aspheric components.
Manufacturing Plan
All optical elements will be fabricated by Optimax Systems Inc. after May, 2015. The final design and wavelength will be chosen by Dr. Wayne Knox and his research group after evaluation.
The last element, the hemisphere, will be fabricated from a Fused Silica glass ball purchased from Edmund Optics3.
Test Plan / Validation
Testing of the optical and mechanical properties of the lenses is done by Optimax Systems Inc. as part of their manufacturing process.
Risk Assessment The main issues arise from the ability to fabricate the design given the tolerances. The tolerances were adjusted accordingly to minimize risk of performance failure due to fabrication. Specifically, certain tolerances were loosed (to levels within high precision, precision, and commercial) to allow for easier manufacturability and a greater chance of attaining performance specifications. The manufacturing probability was modeled using CODE V. with designs being evaluated for a probability of 80% or greater for an RMS wavefront error of 0.05 waves.
Future Steps As of May 1, 2015, the Senior Design project has officially culminated by Joe and Natalie. The next steps in the progress of this general project will be as follows:
1. Present results to Rick Plympton and provide feedback on Estimator software.
2. Pass on designs to Professor Knox and his research group to evaluate each design with consideration of: wavelength, cost/ performance analysis, optomechanical mounting, and possible fabrication.
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Appendix 1. CODEV commands for optimization aut; int y; dra y; wfr y;
!optical parameters EFL Z1 > 5 < 15 !der def
!Manufacturing Parameters OAL S1..11 < 35 > 5
!CT of lenses CT S1 > 2 < 5 CT S2 > 2 < 4 CT S4 > 2 < 5 CT S5 > 2 < 4 CT S8 > 2 < 5 !CT S10 > 2 < 5 Ct S11 > 0.55 < 5
!ET of lenses ET S1 > 1 ET S2 > 1 ET S4 > 1 ET S5 > 1 ET S8 > 1 !ET S10 > 1
!Air Gaps CT S3 > 0.2 CT S6 > 0.2 CT S7 > 0.2 CT S9 > 0.2
RDY S1 > 3 RDY S2 < -3 RDY S3 > 3 RDY S4 > 3 RDY S5 < -3 RDY S6 > 3 RDY S8 > 3 RDY S9 > 3 !RDY S10 > 0.5
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2. Tolerance Values
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3. Hemisphere to be used as the last surface will be purchased from Edmund Optics. The specifications are as follows:
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4.
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5.
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