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In the process of manufacturing the world’s largest silicon carbide (SiC) aspheric mirror, the primary difficulties are mirror blank preparation, asphere fabrication, and testing, as well as cladding and coating. Specifically, the challenges include the homogeneity of the complicated structure casting, accuracy and efficiency of the fabrication process, print-through effect, fidelity and precision of test procedure, stress and denseness of cladding process, the dynamic range of interferometric measurement, and air turbulence error due to the long optical path. To break through such a barrier of difficulties, we proposed the water-soluble room temperature vanishing mold and gel casting technology, homogeneous microstructure reaction-formed joint technology, nano-accuracy efficient compound fabrication, gravity unloading technology, high-denseness low-defect physical vapor deposition (PVD) Si-cladding technology, test data fusion method, and time-domain averaging method, etc. Based on the proposed technologies and methods, we have accomplished the world’s largest SiC aspheric mirror with a size of ⌀4.03 m. The impressive performance of the SiC aspheric mirror is validated by the characteristics of the fabricated SiC aspheric mirror. The aerial density of the SiC blank is less than 120 kg/m2, surface shape test accuracy is better than 6 nm RMS, thickness inhomogeneity of the cladding layer is less than 5%, and the final surface figure error and roughness are 15.2 nm RMS and 0.8 nm RMS, respectively.

Metal mirrors have attracted increasing attention for satisfying the growing demands for high-performance optics in airborne and spaceborne remote sensing systems. Additive manufacturing has enabled the development of metal mirrors with reduced weight and improved strength. AlSi10Mg is the most widely used metal for additive manufacturing. Diamond cutting is an effective method for obtaining nanometer-scale surface roughness. However, the surface/subsurface defects of additively manufactured AlSi10Mg deteriorate the surface roughness. Conventionally, AlSi10Mg mirrors used in near-infrared and visible systems are plated with NiP layers to improve the surface polishing performance; however, this leads to the bimetallic bending because of the different coefficients of thermal expansion between the NiP layers and AlSi10Mg blanks. In this study, a method of nanosecond-pulsed laser irradiation is proposed to eliminate the surface/subsurface defects of AlSi10Mg. The microscopic pores, unmolten particles and two-phase microstructure of the mirror surface were eliminated. The mirror surface exhibited better polishing performance, and it could be smoothly polished to a nanometer-scale surface roughness. The mirror exhibits strong temperature stability owing to the elimination of the bimetallic bending caused by the NiP layers. It is expected that the mirror surface fabricated in this study can satisfy the requirements for near-infrared or even visible applications.

Fringe projector profilometry (FPP) is an important three-dimensional (3D) measurement technique, especially when high precision and speed are required. Thus, theoretical interrogation is critical to provide deep understanding and possible improvement of FPP. By dividing an FPP measurement process into four steps (system calibration, phase measurement, pixel correspondence, and 3D reconstruction), we give theoretical analysis on the entire process except for the extensively studied calibration step. Our study indeed reveals a series of important system properties, to the best of our knowledge, for the first time: (i) in phase measurement, the optimal and worst fringe angles are proven perpendicular and parallel to epipolar line, respectively, and can be considered as system parameters and can be directly made available during traditional calibration, highlighting the significance of the epipolar line; (ii) in correspondence, when two sets of fringes with different fringe orientations are projected, the highest correspondence precision can be achieved with arbitrary orientations as long as these two orientations are perpendicular to each other; (iii) in reconstruction, a higher reconstruction precision is given by the 4-equation methods, while we notice that the 3-equation methods are almost dominatingly used in literature. Based on these theoretical results, we propose a novel FPP measurement method which (i) only projects one set of fringes with optimal fringe angle to explicitly work together with the epipolar line for precise pixel correspondence; (ii) for the first time, the optimal fringe angle is determined directly from the calibration parameters, instead of being measured; (iii) uses 4 equations for precise 3D reconstruction but we can remove one equation which is equivalent to an epipolar line, making it the first algorithm that can use 3-equation solution to achieve 4-equation precision. Our method is efficient (only one set of fringe patterns is required in projection and the speed is doubled in reconstruction), precise (in both pixel correspondence and 3D reconstruction), and convenient (the computable optimal fringe angle and a closed-form 3-equation solution). We also believe that our work is insightful in revealing fundamental FPP properties, provides a more reasonable measurement for practice, and thus is beneficial to further FPP studies. Ministry of Education (MOE) Published version Funding: Ministry of Education - Singapore (MOE-T2EP20220-0008); Youth Innovation Promotion Association of the Chinese Academy of Sciences (2019221); National Natural Science Foundation of China (11903036, 1803037, 61805243, 62127901); Bureau of International Cooperation, Chinese Academy of Sciences (181722KYSB20180015); Key Research Program of Frontier Science, Chinese Academy of Sciences (QYZDJ-SSW-JSC038).

Optical surfaces with high quality have been widely applied in high-tech industries for their excellent performances. To precision manufacture those surfaces efficiently and effectively, various machining technologies involved become extremely crucial. As one of the promising ultra-precision machining technologies, inflated or solid elastic tool polishing has attracted more attention for its own superiority. However, there is still lack of understanding on material removal mechanisms especially with the consideration of curvature effect, and it is of great importance to determine the surface quality and form control in ultra-precision polishing process. In this paper, originating from the famous macro-scale Preston equation, the curvature effect-based material removal model in polishing using a flexible ball-end tool has been developed successfully on the basis of two key sub-models, one is the generic model of effective relative velocity and the other refers to the semi-experimental contact pressure model. A series of spot polishing experiments subsequently are conducted on concave surfaces with a curvature radius range from 75 mm to 225 mm. The experimentally measured section profiles of polishing spots do match well with the predicted data, which verifies the effectiveness of the proposed material removal model. On the measured polishing spots, it is also observed that there have two nonuniform material removal phenomena, one is analyzed along the central axis and the other is discussed by two regions symmetrical about the central axis. Compared with the effective relative velocity, it is found that, the contact pressure is more sensitive to curvature effect by investigating the variation of maximum removal depth within a broader curvature radius range from 75 mm to 1000 mm. This study can provide a valuable foundation for polishing optical surfaces with deterministic removal.

Large aperture, lightweight optics are frequently utilized in modern optical systems. However, despite the use of advanced techniques for developing their materials, fabrication, and mechanical structure, the coatings placed on the substrates induce slight lattice mismatches and increase the thin film stress on polished surfaces. This significantly distorts nano-accuracy optical surfaces, especially on lightweight freeform surfaces. In this study, we construct a finite element model (FEM) and a ray tracing model to estimate the impact of the stress-induced deformation of the coating on a 1.5m class lightweight silicon carbine (SiC) mirror with a freeform surface. Our simulation results are within 10% deviation from the experimental results, and the deformation texture map matches these results as well. We discuss several possible strategies to overcome stress-induced deformation, including fabrication pre-compensation, lightweight structure redesign, and an inverse print-through effect.

Spectral imaging technique, which retrieves both spatial and spectral information of a scene or an object, is an important tool in applications such as food inspection, vegetation monitoring and geographic remote sensing. Most spectral imaging systems have a complex system architecture, in which different components are used for different functions, limiting the efficiency of information retrieval. Here, we propose a hyperspectral imaging system with a simple architecture, where a multiplexing digital micromirror device functions both as a spatial light modulator for spatial imaging and a diffractive grating for spectral measuring simultaneously. The proof-of-principle system contains a group of lenses, a digital micromirror device and a one-dimensional detector array, and is capable of performing 128 × 128 pixel resolution hyperspectral imaging over the visible spectrum with an experimental 3.73 nm spectral resolution. Furthermore, by using a compressive sampling strategy, continuous real-time spectral video is performed with a frame-rate up to 10 Hz. The concise architecture of the proposed system, with the potential to be easily extended to both ultraviolet and infrared, offers an alternative scheme to manufacture low-cost, compact, hyperspectral imagers.

The ptychographic iterative engine (PIE) is an algorithm for coherent lens-less diffraction imaging. It facilitates the development of low-cost large field of view (FOV) lens-less microscopy, as it can expand the FOV extensively by moving the light source or the bio-medical pathological sample slide. In a PIE setup, the illumination light needs to have high/partially coherence. Thus, to get a colorful microscopy image, more than 3 illumination light sources with different dominant wavelengths are required in a traditional PIE setup. In this manuscript, an improved PIE based on computational deep learning color-transferring method is proposed to achieve colorful large FOV lens-less microscopy imaging. In our method, only one high/partially coherent light source is used, where the image data are three times less than those images under multiple illuminations for colorful PIE microscopy. It is believable that our colorful PIE microscopy enhanced by the deep color-transferring method would be helpful for the development of low-cost large FOV lens-less microscopes.

Amounts of cost-effective biological observing and detecting instruments are needed in biology and medical applications. In these demands, a low-cost, portable microscope with light-weight and tele-communication, is very attractive in the resource-limit area. In this manuscript, a portable singlet phase contrast microscope based on smart-phones are proposed. In the optics hardware, an external singlet lens is designed and closely attached before the rear cameras of a smart-phone, which constructs the imaging part of a simplified microscope. And a circular oblique illumination is adopted. In the computational imaging part, the in-focus images recorded by the smart-phone are virtually enhanced and style-transferred to phase contrast images by deep learning methods. Through pairs of experimental image data, we train the deep learning network and demonstrate the effectiveness of this virtual phase contrast imaging approach using multiple samples, e.g., unstained/transparent tumor tissue pathological slide, and H&E (Hematoxylin and Eosin) stained tumor tissue pathological slide. Our results provide a powerful example of low-cost portable phase contrast microscope with high-speed tele-communication abilities in the 5G + mobile internet era.

The phase type computer generated hologram (CGH) plays an important role in aspherical surface optical testing, especially for low reflectivity material mirror surfaces, owing to its high diffractive efficiency. With the increasing demand for high precision CGHs, traditional methods such as reactive ion etching and focusing ion beam, have difficulty realizing the fabrication of a large aperture and high accuracy phase type CGH. In this study, fabrication of a high precision CGH has been demonstrated via a new method called scanning ion beam etching (SIBE), which is suitable for most common optical materials and the fabrication of high performance CGH. On the basis of the movable radio frequency ion source, we determine an etching depth calculation method to realize high accuracy etching regardless of whether the removal function is a perfect Gaussian distribution. Experiments are conducted to verify the etching depth accuracy. Moreover, the linewidth, sidewall angle, roughness, and etching uniformity results of the CGH are superior to the fabrication of CGH via the conventional method. As a proof of concept, a phase type CGH with an aperture of 80 mm is fabricated, and the wavefront accuracy is 6.2 nm, which can meet the processing requirements of a high precision aspheric mirror. Thus, a SIBE method is developed for high performance CGH, which may aid in the development of high accuracy diffractive optics.

Singlet lenses are free from precise assembling, aligning, and testing, which are helpful for the development of portable and low-cost microscopes. However, balancing the spectrum dispersion or chromatic aberrations using a singlet lens made of one material is difficult. Here, a novel method combining singlet lens microscopy and computational imaging, which is based on deep learning image-style-transfer algorithms, is proposed to overcome this problem in clinical pathological slide microscopy. In this manuscript, a singlet aspheric lens is used, which has a high cut-off frequency and linear signal properties. Enhanced by a trained deep learning network, it is easy to transfer the monochromatic gray-scale microscopy picture to a colorful microscopy picture, with only one single-shot recording by a monochromatic CMOS image sensor. By experiments, data analysis, and discussions, it is proved that our proposed virtual colorization microscope imaging method is effective for H&E stained tumor tissue slides in singlet microscopy. It is believable that the computational virtual colorization method for singlet microscopes would promote the low-cost and portable singlet microscopy development in medical pathological label staining observing (e.g., H&E staining, Gram staining, and fluorescent labeling) biomedical research.

The thin mirrors are widely used in active optical system. In this letter, magnetic medium assistant polishing (MMAP) technology and device are discussed for thin mirrors optical finishing. The principle of MMAP is introduced, the magnetic tool for polishing is designed, and the removal function of magnetic polishing tool is studied. On the basis study of the material removal function especially removal property in the edge region, the tool-path is optimized, and the dwell time distribution of computer-controlled MMAP is researched. The glass thin mirror is polished by MMAP technology. The diameter of the work-piece equals S22201 150 mm and the thickness is 5 mm. The initial surface error is 0.19\lambda (root mean square (RMS)) , and after two steps fabrication, the final surface error reaches 0.02\lambda. The experimental rsults verify that the technology is effective for thin mirrors finishing.

In deterministic computer-controlled optical surfacing, accurate dwell time execution by computer numeric control machines is crucial in guaranteeing a high-convergence ratio for the optical surface error. It is necessary to consider the machine dynamics limitations in the numerical dwell time algorithms. In this paper, these constraints on dwell time distribution are analyzed, and a model of the equal extra material removal is established. A positive dwell time algorithm with minimum equal extra material removal is developed. Results of simulations based on deterministic magnetorheological finishing demonstrate the necessity of considering machine dynamics performance and illustrate the validity of the proposed algorithm. Indeed, the algorithm effectively facilitates the determinacy of sub-aperture optical surfacing processes.

Silicon (Si) modification layer on silicon carbide (SiC) surface is widely used in space optical systems. To achieve high-quality optical surface, the technology of ion beam figuring (IBF) is studied. The radio frequency ion beam source is introduced briefly. Then the removal function experiment is studied. The volume removal stability of the IBF reached 97% in 10 h continuous working testing. The parameters of the IBF removal function are calculated by Gaussian fitting including the removal rate and the full-width half-maximum. Then the removal function results are used in practical fabrication. The workpiece is a plane with Si modification layer on SiC surface. After 148 min processing IBF, the final surface error reaches 1.2 nm RMS.