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Computer-generated holograms (CGHs) allow to transfer the high 2D-positioning accuracy of modern lithography equipment into high precision 3D-shape measurements, e.g. in CGH asphere metrology. In this contribution, we give a detailed look into the characterization of steep topologies with CGHs on the example of a 90 deg axicon surface, requiring rather high line densities in the hologram. Several aspects gain importance with increasing CGH line densities when measuring dimensional quantities such as the cone angle of the surface: misalignment of the setup, fabrication effects of the CGH rigorous effects of the high density grating, and effects due to wavelength variations of the interferometer. This paper presents the experimental approach for the cone angle measurement and a systematic analysis of its measurement uncertainty, focusing on the specifics of this null test CGH measurement.

The authors have successfully employed the charged particle nanopatterning (CHARPAN) technology for nanostructuring of a metal mold insert for a conventional injection molding machine. High-precision diamond-milled Ni–Cu mold inserts have been nanopatterned with 10 keV argon ion multibeam milling with feature sizes as small as 50 nm. A variety of structures such as circles, hexagons, and lines in different dimensions, with positive and negative shapes, have been fabricated in the metal mold. These structures have been successfully replicated in polymethylpentene samples by injection molding. To the authors’ best knowledge, the CHARPAN technology is one of the very few technologies that allow for resistless nanostructuring a field size of 25×25 μm2 into a metal mold in a single shot. This is of high importance for the practical injection molding fabrication of nanostructured polymer devices such as optical biosensors.