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Introduction
The manufacture of micro-optic lenses for the mobile phone industry continues to grow with the increased use
of smartphones. The mass production of micro-optic lenses has become easier than ever, particularly since the
introduction of molding techniques for glass lenses and injection molding methods for the popular plastic lens.
The ease in making aspheric and other structured lenses makes automated production of these lenses possible, and
significantly reduces the lens production time. In addition, to the use of plastic injection or glass molding techniques,
advanced coating technology has greatly reduced mass production costs.
Measurement techniques
Due to the requirements of the mobile phone lens mold industry a fast, accurate 3D non-contact
measurement technique with large slope measurement capability and flexibility is desired.
Contact measurement techniques are used by most lens mold industries for quality control of the lens mold.
These kinds of measurement lack flexibility for checking relationships between the axes, such as the absolute
position error of the aspheric lens mold to its peripheral rim/shafts. Non-contact techniques such as CSI
(coherence scanning interferometry), are not suitable for smart phone lens mold measurement, due to the
limitations of slope measurement for the objective lens. For scanning confocal microscopy, although the
surface slope capability is much improved in comparison to CSI; its limited vertical range, long measurement
time and inability to measure lens off-axis error excludes it from smart phone lens mold applications.
The scanning process is accomplished by means of a MWLI point sensor, its position being controlled by 2
precise linear stages and 1 precise rotary stage. The MWLI point sensor continuously measures the distance
to the object surface by following a programmed curve, while the object is rotated on a high precision air
bearing spindle, so as to perform a spiral scan over the whole surface. As a result real 3D topography can
be obtained quickly (normally in a few minutes) to reveal the true surface form error from the designed
shape and the defects of the object surface.
LuphoScan platform
- Multi-Wavelength Interferometry (MWLI)
Metrology frame
Two linear
4 axis geometry: reference stages
-- 2 linear roller bearing stages
(R, Z positioning of the probe)
One rotary
-- 1 rotational roller bearing stage reference stage
(T tilt of the probe)
-- 1 rotational air bearing stage
Object probe
(C rotation of the object)
Independent metrology frame to compensate for Object
axial errors in the principal plane
C-axis
3 reference probes determine the position of the
object probe within the reference frame
Temperature compensation
Case study
In this note, the measurement method of a LuphoScan system is illustrated using an example of a very
small lens mold measurement.
Procedures
Measurement of the aspheric optical surface form.
Position error measurements of the aspheric optical surface to the user defined
reference ring/shafts
a. Measure tilt error with the user defined reference rim along with its height with
respect to the optical surface form axis
b. Measure decenter (with plane A)
c. Measure decenter (with plane B)
Notes - the reference ring/planes and axes for calculating the position errors including the decenter errors
and tilt errors, can be defined freely by the user such as roundness planes or 3D cylindrical sections
All the measurements were completed automatically in one cycle, without operator intervention. The user
only needs to type in the aspheric designed parameters once and select the desired reference rim/planes
or 3D cylinders before the measurements. The lens mold form measurement was completed in about 3
minutes, the position error measurements were done in 3 minutes. All the required results, such as form
error and position errors, can be displayed at the end of the measurement.
Summary
A LuphoScan system combines the advantages of high precision non-contact 3D profilometry, and
large slope measurement capabilities. It is a fast, non-destructive, precise and function flexible 3D non-
contact metrology tool. Accurate 3D topography of the lens mold and its position errors can be obtained
automatically within a few minutes.
LuphoScan systems can greatly help the lens mold manufacturer to improve the optical surface of a lens
mold and its position relative to the mold rim and mold mounting shafts.
A140 Advanced contact and non-contact metrology for characterisation of optical lenses
Lucy Cooper, Applications Engineer
Introduction Challenges
A manufacturer of steep- Steep-sided miniature aspheres are found in many Steep-sided aspheric molds for small optics are
sided molded lenses had applications such as blu-ray and standard DVD among the most demanding of todays ultra-high
optics, cell phone camera lenses, digital camera Application
precision form note measurementA140:applications
Optical and lenses
serious yield problems with lenses, high power LEDs and fibre coupling present a number of challenges in obtaining highly
lenses and molds, which optics. Obtaining highly accurate and repeatable accurate and repeatable data.
measurements of the molds that produce these PGI and CCI contact and non-contact techniques
were difficult to manufacture 1. Steep sides There are two fundamental
steep-sided miniature aspheres is critical for both
due to the steep slopes and
tight tolerances involved.
design improvement and manufacturing process
control. Advanced contact and
issues here, the first is to avoid any stylus flanking
at all as this totally invalidates the data set (see
Figure 3a). Secondly, even if flanking is overcome
PGI Dimension helped to
improve their process control
In this application note we identify some of
the measurement challenges faced by profile
measuring instruments and explain how Taylor
non-contact metrology for
by a special stylus, many measurement systems
will show a progressive deterioration in data
Hobsons PGI Dimension addresses these by
yields by over 10%.
Unique measurement
and non-contact (CCI) metrology
lenses has significantly reduced the number of have employed aspheric and diffractive optics
factors. for chromatic aberration arising from the
proceed with an introduction to each technique.
to reduce the number of lenses needed: refractive properties of the lens.
one aspheric or diffractive lens can replace
Typical applications Key parameters lens form
capability for steep-sided
several conventional spherical lenses and as a
www.taylor-hobson.com
Mobile phone cameras Advanced metrology Taylor Hobsonfor optics
2013
result the weight, cost and space used are all and roughness
A143 New software to reduce set-up time for grinding and diamond
DVD read/write heads reduced, achieving a more compact and better Lens form is one of the most important optical
small hemispheres
Bar-code scanners With the rapid evolution of optics, suitableperforming optical system.
advanced metrology tools are necessary design parameters used to control the quality of
High power LED optics for characterizing lenses with more complex shapes, of various sizes and made of precision aspheric and asphero-diffractive optics,
Blu-Ray DVD optics different materials. A number of metrologyDiffractive tools havelenses
beenare normallytoused
employed by optical
measure the ensuring they perform as required. In addition,
aspheric and asphero-diffractive lenses. Fordesigners instance,tocontact
correctstylus
for chromatic aberration
profilometry and surface roughness affects performance. It is
Cameras
non-contact interferometry techniques. and aspheric optics can be used to reduce or Lucy Cooper, Applications Engineer
Projectors eliminate spherical aberration, thereby improving therefore essential to use the very best and most
turning
Automotive and medical Phase Grating Interferometry (PGI) is a contact focusstylus profilometry,
quality. Diffractivewhich
opticscan offer new
provide largerand efficient measurement techniques.
as and Introduction
Application note A143: New software
The main to reduce
challenges are: set-up time for grinding and diamond turning
Head-up displays (HUD) gauge range to resolution when compared with other degrees
powerful tradionalofprofilometers,
freedom for lens suchdesign In this application note we provide some
Infra-red thermal imaging inductive gauges and laser interferometers. Coherence Taylor
result in highCorrelation
quality dataHobson has designed
Interferometry
from optical (CCI)
systems. In examples
order to haveof theconfidence
measurement in a of
measurement
aspheric and Sample has steep sides There are two
for rescue and security instruments provide advanced 3-dimensional non-contact surface characterization. The
the PGI Dimension to meet process, it is essentiallenses
asphero-diffractive to achieve
using results which PGI
both contact X offsetissues
fundamental compensation
here, the first is to avoid any
Astronomy technique is fast and accurate and provides aMore recently, the
high resolution use of together
3D image asphero-diffractive
with are(PGI)
highlyand
repeatable
non-contactand(CCI)
also traceable
metrologytoand we stylus flanking at all as this totally invalidates the
Spectroscopy analysis that includes 3D roughness, 3D formlenses analysishas
andsignificantly
profile reduced the number
measurements. international
proceed with standards.
an introduction to each technique. data set.
Optical communications of modern optics applications.
In this Application Note, a traceable calibrated
Biomedics Typical applications Bob Bennett, Technical standard is measured on Taylor Hobsons PGI Secondly, even if flanking is overcome by a
Infra-red thermal imaging inductive gauges and laser interferometers. Coherence Correlation Interferometry (CCI) rotational axis. This is particularly important if
for rescue and security instruments provide advanced 3-dimensional Small non-contact
diameter surface
opticscharacterization.
Thearenew AAU the
amongst Themost
software Diamond
profilesturning is often
are taken used toangular
at different manufacture PGITen
positions Dimension traceability
diamond turning customers in America
technique is fast and accurate and provides a demanding high resolution 3D image togetherprecision
with form highare quality
Astronomy of todays ultra-high
from Taylor Hobson has taken.aspheric elements taken
A measurement used inoff axis may were approached with a survey to determine
Definitive assessment of
Spectroscopy analysis that includes 3D roughness, 3D form analysis and 2D profile measurements. optical assemblies in telescopes, lasers, videoIt is the effect of Taylor Hobsons X-offset and radius
and radius measurement applications. They result in significant measurement errors.
Optical communications
increased our capability to projectors and numerous other systems and error compensation capabilities. The average
present a number of challenges in obtaining therefore critical that the instrument alignment
Biomedics highly accurate and manufacture
repeatablehigh data.accuracy
A traceabledevices. Diamond turning is a multi-stage savings on set-up time are 330 hours per year.
process is repeatable and well defined and
of process.
radius accuracy and form
hemispherical standard isInfrared opticsway
an excellent with In the final stages of the manufacturing The larger benefit will be the scrap / rework
that the instrument has high inherent accuracy
www.taylor-hobson.com proving the process capability. Taylor Hobson
enhanced 2013 process,
diffractive
a diamond tipped lathe tool is used to reduction due to the X-offset compensation
and stability.
achieve The smaller
sub-nanometre levelthe sample
surface and
finishes for the effects of the temperature drift in the
analysis capabilities. andthe steeper the sides the more critical this
and requires the measurement system be highly Coherence Correlation Interferometry (CCI)
The PGI Dimension has Ultra-high precision optical systems and
In addition to this X-offset feature, Tayloraccuracy, Taylor Hobson opticaluse leadingmicro-optic
devices, class lenses lenses are typically used in mobile profilometry are no longer suitable
count on day after day.
Hobson and Precitech have developed software accuracy R22.5 mmincluding and R12.5 smallmmspherical
calibration
lenses, phone cameras, other different types for the measurement of these micro-
that enables the machine and metrology to balls (Figure 2) provided
asphericby lenses
the SwissandFederal
lenses with of illumination. Small artificial IOL lenses, due to possible soft or fragile
Yann Guimond
communicate with each other. This enables Institute of Metrology (METAS).
structured Radiussuch as small
surfaces; (Intraocular lens) lenses are implanted surfaces. There are also complicated
automatic correction of theGeneral
X-offset Manager
and tool uncertainty of these calibration balls is within
diffractive lenses, Fresnel lenses and inside the eyes to correct focusing factors, such as high aspect ratio
radius errors, providing UMICORE
a significant IR GLASS in 50 nm and calibration
reduction is carriedlenses;
out by
intraocular area micro
getting more errors for cataract patients to regain structures for some diffractive lenses,
set-up time and improved process performance. CMM.
and more popular. These micro-lenses their vision. arising from the small size of the
have a wide range of applications. For components and high contact pressure
www.taylor-hobson.com example,small
Taylor Hobson 2013
collimation Micro lenses, whether with structured
lens forFig. 1: METAS of the stylus. Advanced non-contact
certificate of calibration ball
optical fibre, micro-diffractive lenses are surfaces or without, provide very metrology tools are urgently needed
used for vision correction, colour laser challenging topics for designers, to control the quality of micro optics.
Fig. 2: R22.5 mmprojection mm light-weight low lost manufacturers and metrologists.
and R12.5displays,
calibration balls infrared imaging, mobile phone
Cell-phone
CCI measurement provides
Form error
Roughness
Step heights
Derived coefficients and conic constants
Base radius
www.taylor-hobson.com Taylor Hobson 2013
Defects
Intraocular
lens
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