In the high-stakes world of optical component manufacturing, precision is not just a goal; it’s an absolute necessity. This is particularly true for large-aperture optical components, which are crucial in fields ranging from semiconductor fabrication to aerospace and energy production. Traditionally, measuring the surface profiles of these components has been a painstaking process, reliant on phase-shifting methods that require multiple interferograms and a stable environment. However, a groundbreaking study led by Liang Tang from the Beijing Institute of Technology’s MIIT Key Laboratory of Complex-field Intelligent Exploration is set to revolutionize this process.
Tang and his team have developed a high-precision, large-aperture single-frame interferometric surface profile measurement (LA-SFISPM) method based on deep learning. This innovative approach promises to deliver dynamic, high-accuracy measurements without the need for a phase shifter, significantly enhancing the efficiency and reliability of optical component manufacturing.
The traditional phase-shifting approach, while effective, has its limitations. It demands a high degree of environmental stability and involves collecting multiple interferograms, making real-time measurements challenging. Tang’s method addresses these issues head-on. By training the system with data from small apertures and using contrast learning and feature-distribution alignment, the team has achieved high-precision phase reconstruction of large-aperture optical components.
The results speak for themselves. In tests conducted on a mirror with an 820 mm diameter, the LA-SFISPM method produced a surface profile with a maximum single-point error of just 4.56 nm. The peak-to-valley (PV) value was 0.0758 λ, and the simple repeatability of the root mean square (SR-RMS) value was an impressive 0.00025 λ. These measurements align closely with those obtained using the ZYGO system, a gold standard in the industry.
But perhaps the most striking aspect of this new method is its speed. Tang’s approach reduces measurement time by a factor of 48 compared to traditional phase-shifting methods. “This significant reduction in measurement time is a game-changer,” Tang explains. “It allows for more efficient, rapid, and accurate surface profile measurements, which is crucial for industries that rely on large-aperture optical components.”
The implications for the energy sector are particularly noteworthy. In fields such as inertial confinement fusion, where precision and efficiency are paramount, this new method could lead to significant advancements. By enabling faster and more accurate measurements, it could accelerate the development of next-generation energy technologies, potentially leading to more sustainable and efficient energy production.
The study, published in the English-translated ‘International Journal of Extreme Manufacturing,’ marks a significant step forward in the field of optical component measurement. As Tang and his team continue to refine their method, the future of large-aperture optical component manufacturing looks brighter than ever. This research not only addresses current challenges but also paves the way for future innovations, promising to shape the landscape of optical component measurement for years to come.
