Center for Freeform Optics (CeFO).<\/a><\/p>\nCeFO, which was recently awarded a second five years of funding from the National Science Foundation, is a collaboration between Rochester, the University of North Carolina at Charlotte, and 17 companies and research institutes. The goal is to advance the use of lenses and mirrors with freeform surfaces to create optical devices that are lighter, more compact, and more effective than ever before. Applications include 3-D imaging and visualization, augmented and virtual reality, infrared and military optical systems, efficient automotive and LED lighting, energy research, remote sensing, semiconductor manufacturing and inspection, and medical and assistive technologies.<\/p>\n
This is a newly emerging technology, and Bauer is grateful to be in on the ground floor.<\/p>\n
Bauer is principal designer of a compact telescope that CeFO is creating using three freeform mirrors that are up to 260 mm in diameter. For the last two years he\u2019s worked closely with Nick Horvath, a PhD student in mechanical engineering at UNC Charlotte, who is developing the opto-mechanical design and researching methods that will be used to create a prototype of the freeform telescope.<\/p>\n
Getting the mechanical and optical features just right has involved some tradeoffs. \u201cI think initially the system we designed for them was too sensitive in terms of what is feasible at their end,\u201d Bauer says. So, the design team made some adjustments to the optical elements, but also \u201cworked with (UNC Charlotte) to think of a different route in terms of assembly.\u201d<\/p>\nNick Horvath, a PhD mechanical engineering student at the University of North Carolina at Charlotte, is conducting the opto-mechanical design and\u00a0 researching methods for a full system prototype of a freeform telescope being created by the Center for Freeform Optics. Here he holds a novel mirror mounting system to meet some of the challenging assembly tolerances of the freeform optical design. (Photo courtesy of University of North Carolina at Charlotte)<\/figcaption><\/figure>\nHorvath and Bauer have worked closely to understand\u00a0the tradeoffs between the performance of the system, the accuracy of the mirrors and the telescope assembly, and the costs to fabricate and test the system. Horvath is\u00a0developing methods for fabrication of the complex mirror shapes and has also worked closely with Bauer to develop a novel telescope assembly system.\u00a0 The goal of the system is a repeatable assembly procedure that\u00a0minimizes the amount of costly fine-tuning that must be done to realize the desired performance goals.<\/p>\n
\n
The Center for Freeform Optics is a collaboration between Rochester, the University of North Carolina at Charlotte, and 17 companies and research institutes:<\/strong><\/p>\nAir Force Research Laboratory
The exchange illustrates:<\/p>\n
\nhow close collaboration between mechanical and optical designers enables truly novel research within the CeFO<\/li>\n the respective strengths that the two universities bring to the collaboration: Rochester is strong in design and theory, UNC Charlotte is strong in manufacturing and precision mechanical design, and both take pride in their metrology skills.<\/li>\n what CeFO director Jannick Rolland considers to be one of the key achievements of the center\u2019s first five years: a full adoption and expansion of \u201cconcurrent engineering\u201d required for projects like this.<\/li>\n<\/ul>\nIn other words, making sure designers in Rochester are working hand-in-hand with the mechanical engineers at Charlotte \u201cfrom the beginning, so that you don\u2019t spend a lot of time designing something that isn\u2019t going to work.\u201d<\/p>\n
\u201cWe\u2019ve evolved a very good back and forth between design, manufacture, and measurement,\u201d says Thomas Suleski, professor of physics and optical science at UNC Charlotte and new director of the CeFO team there.<\/p>\n
Achievements and goals<\/strong><\/h3>\nRolland, the Brian J. Thompson Professor of Optical Engineering, cites these other accomplishments:<\/p>\n
\nA new methodology for designing freeform optics that removes much of the guesswork was published earlier this year in Nature Communications<\/em>, with Bauer as the lead author. \u201cI really feel we\u2019ve nailed key components of the design space,\u201d Rolland says.<\/li>\nTwo hardware prototypes have been completed \u2013 a compact freeform spectrometer and a down-scaled version of the freeform telescope.<\/li>\n Seven patents have been awarded.<\/li>\n Total annual revenues are now in excess of $1 million.<\/li>\n About 30 percent of the students and faculty involved with CeFO are women.<\/li>\n There has been a significant increase in participating companies and institutes from an initial 8 to 17. \u201cThe interest is clearly picking up; it is a very exciting time in the discovery of what freeform optics can do and the understanding of the science that underlies the emerging results\u201d Rolland says. Members and faculty determine the center\u2019s 14 ongoing projects; membership fees and supplements fund the projects.<\/li>\n<\/ul>\n\u201cFreeform optics is poised to permeate all precision technologies of the future, and perhaps a lot sooner than we ever anticipated,\u201d Rolland says.<\/p>\n
In addition, one of the longest-lasting effects of CeFO is the \u201cdevelopment of a new generation of young scientists who are trained at UNC Charlotte and Rochester,\u201d says John Lambropoulos, professor and chair of mechanical engineering and CeFO\u2019s associate director. \u201cThe students, ranging from undergraduates to masters students to PhDs to post docs, represent a broad spectrum of backgrounds.\u201d<\/p>\n
And the constant contact with industry as well as CeFO faculty \u201crepresents a new way of learning and teaching, where industry itself is the third partner in the student\/teacher intellectual relationship,\u201d Lambropoulos says.<\/p>\n
\u201cLightPath\u2019s involvement in CeFO has pushed us to become an expert in molded freeform optics that would not have been otherwise possible,\u201d says Alan Symmons, the company\u2019s executive vice president of pperations. \u201cBy working with world class companies and Universities we have developed our manufacturing and metrology processes to a level we would not have been able to achieve on our own. CeFO has provided our team with access to equipment, facilities and most importantly talented individuals, allowing us to leapfrog our competition and become a frontrunner in the development and application of glass molded freeform optics.\u201d<\/p>\n
CeFO\u2019s goals for the next five years include advancing the metrology (measuring of freeform surfaces) to ensure quality, and finding ways to mass produce freeform optics quickly, using a variety of materials, for large consumer markets. One intriguing possibility: Molding transparent ultraviolet-cured polymer materials so they can be applied, almost like contact lenses, to traditional glass lenses and mirrors, giving them a freeform surface.<\/p>\n
\u201cThere\u2019s an evolution in the education process that is still happening, as companies learn more about what freeform optics can really do,\u201d says Suleski.\u00a0 \u201cMany companies are still only thinking of freeforms in terms of tiny changes to existing symmetrical elements\u2026.they aren\u2019t thinking far enough outside the box.\u201d<\/p>\n
\u201cOnce you start to think away from these classical designs, it should be possible to take multiple optics and with one freeform optic turn them into one,\u201d says Matt Davies, a professor of mechanical engineering and engineering science, who served as prior director of the CeFO team at Charlotte. \u201cSo that the price of making the device is more than overcome by the reduction in assembly steps, the reduction in the number of optics, and the compactness.\u201d<\/p>\n
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