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output nominal performance, but when they start applying manufacturing errors, they will know that the system is less sensitive to them.’
This in turn permits more flexibility in design, as less sensitivity means less stringent manufacturing constraints are required.
‘Engineers can have greater confidence
that their design, once it’s built, will meet its specifications. There is more confidence that a higher number will meet those specifications and the higher the yield the lower costs become,’ Normanshire noted.
More design ability, no extra computing power Computing the actual sensitivity to optical tolerances is computationally expensive and time consuming, but this overhead is avoided within High-Yield Optimization by using the angles of incidence as a proxy for the actual tolerances. This speeds up the numerical optimisation. As rays of light travel through a lens,
the larger the angle of incidence (AOI), the larger the aberrations that will be generated as the ray bends at that surface. Zemax’s OpticStudio software aims to improve the performance of the system by reducing AOIs as they travel through the designed
system and hit different surfaces. Going one step further, High-Yield Optimization uses AOIs to simulate how manufacturing and assembly will affect AOIs, using the same ray simulations. ‘We utilise those same rays – so there is no extra computational overhead – and each time a ray hits a surface, work out the AOI and look to minimise that. If we do that as making the smallest focal spot, if that’s what we’re looking for, we’ll create a design that performs well but also is less sensitive to those induced errors,’ said Normanshire. ‘Effectively we trace one set of rays
through a system, and use them both to calculate the optical performance but also inform us how and create a penalty that reduces the sensitivity to a design by looking at the AOI at every surface,’ Normanshire continued. ‘In the user interface, it’s a simple checkbox. That’s one of the clever things about it – you can incorporate this into any design you want.’ Zemax’s High-Yield Optimization gives optical designers the capability to improve yields, reduce costs and design with more confidence and flexibility. With this advance on traditional design approaches, systems will have good performance when built in the real world, rather than just in a computer simulation. EO
“The feature doesn’t require any additional knowledge, it’s something that anyone can start incorporating into their design process”
New White paper High-Yield Optimization Streamlining the path to more easily manufacturable designs
The conventional optical design approach results in designs that are very sensitive to manufacturing and alignment errors, which means the optical product is difficult to repeatedly manufacture successfully.
A new method, called High-Yield Optimization, produces designs that meet tight performance specifications, provide a higher manufacturing yield, and lower manufacturing costs through less waste.
Learn how to:
• Optimize for as-built performance, rather than nominal performance.
• Account for common manufacturing defects in the design process.
• Find optical design solutions that have both good image quality and rays with low angles of incidence, which reduces the tolerance sensitivity of the resulting design when fabricated.
www.electrooptics.com/whitepapers
Electro Optics
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