SBIR-STTR Award

The work proposed here is to develop and demonstrate softwarethat provides a simulation of optical surface errors produced duringmanufacturing processes that use tubular grinding. The software will bedesigned with reference to the Opticam SM and SX precision grindingmachines. The tubular grinding process used in the Opticam machines is adeterministic method that promises to enable concurrent engineering ofoptical elements in an agile manufacturing environment. Unlike conventionaloptical manufacturing processes that require extensive hand work, Opticamtechnology produces optical surfaces having shapes that are accuratelydetermined by the geometry of the grinding machine. Surface errors producedduring tubular grinding are closely related to the relative alignment ofthe tool and workpiece. This makes it possible to predict the errorsproduced by various types of misalignment, and thereby make it possible tocorrect the alignment of the machine by inspecting a manufactured part. InPhase I, we will develop and demonstrate prototype software for predictingsuch surface errors, formulate the concept of interfacing to commerciallyavailable optical design software, and formulate the concept for making thesoftware an integral part of the Opticam manufacturing process.

This project will create innovative software that integrates optical design and manufacturing. It will enable concurrent engineering involving both lens designers and optical engineers. It will extend the concepts and demonstration software developed in Phase I to support the entire compyer integrated manufacturing program (Opticim) at the Center for Optics Manufacturing (COM) at the University of Rochester. The software will maintain a database of information needed to manufacture optical elements, will carryout basic optical analysis, produce optical drawings, design Opticam tooling, and develop manufacturing process plans. It will have an interface to commercial optical design, interferometric measurement, numerical control, and other support programs that each provide part of the overall information system needed for the success of the project. The development of new deterministic microgrinding and process science at COM have provided the basis for agile optics manufacturing. To be successful, they must be supported by equally innovative software. This project will create a working program that can be used internally at COM as a test bed for new manufacturing information systems. After its successful demonstration at COM, Sinclair Optics plans to undertake a Phase III project to commercialize the program for general use.