During design and manufacturing, optical systems and lenses are toleranced and tested to ensure the smallest possible performance error. Matching most optics manufacturing companies’ capabilities, lenses are traditionally toleranced with individual surface specifications — surface power and irregularity, or form, error. These tolerances and the associated tests control performance of a single surface, not the entire lens.

Because lens designs are built around transmission characteristics such as spot size and RMS wavefront error, the performance of the entire lens, not the individual surfaces, is the true target. Transmitted wavefront error (TWE), which is the error in transmission of light through a lens, is the true target. For aspheric surfaces, traditional single-surface, three-dimensional surface form metrology is not easy. Aside from testing the true target, it may be easier and faster to make use of TWE for aspheric lenses. Using innovative metrology and developing a feed-forward manufacturing strategy, tolerancing and testing TWE can reduce risk in optical designs, improve performance and reduce cost and lead time....

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