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Application note A150: Smart phone lens mold

LuphoScan (3D non-contact)

Fast and highly accurate


metrology tool for smart phone
lens mold characterization
Yang Yu, PhD Senior Applications Scientist,
Gernot Berger, PhD Business Development Manager

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.

Manufacturing process flow for micro plastic lenses

Lens Design Mold Design Mold Making Injection

Package Quality control Measurement Coating

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Application note A150: Smart phone lens mold 2

Importance of the lens mold measurement and its key parameters


Quality control of lens molds is very important for lens development and production, particularly for the
popular plastic lens, whose quality is mainly depends on the lens mold. Precise measurement of the camera
lens mold is becoming more challenging for metrologists seeking to optimise the complete process chain in
an industrial environment. This is because the slope of lens surfaces is getting steeper (up to ~65 or more),
their size is getting smaller (down to ~1mm), and tolerances are getting tighter in the lens mold industry.
The common type of lens mold used in most industries is an aspheric shape. Aspheric form error and the
absolute position error to the peripheral rim/mold mounting shafts are important parameters because they
are directly reflected in the quality of the lens products. These factors affect the focus quality, and therefore
reduce the optical efficiency.

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.

Smart phones Lens mold manufacturing Smart phone lenses

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Application note A150: Smart phone lens mold 3

Advanced optical metrology tool for lens mold (LuphoScan platform)


- Multi-Wavelength Interferometry (MWLI)
The LuphoScan platform is a patented interferometric scanning metrology system based on multi-
wavelength interferometry (MWLI). The systems are designed to perform precise non-contact 3D form
measurements, mainly of rotationally symmetric surfaces such as aspheric lenses. The system is based on a
combination of scanning four-axis geometry and a non-contact interferometric (MWLI) probe. The basic
principle for measuring the 3D form error of spherical, aspheric or other rotational objects, is that the probe
is guided in a programmed curve over the surface of the object such that the distance between the probe
and the object is kept constant and the probe is always presented perpendicular to the surface of the object.
The absolute measurement capability of the MWLI sensor technology makes its function flexible, even
catering for surface measurements such as segmented objects as it allows for interrupted beams.

Benefits of LuphoScan measurement


Non-contact
3D
Super-fast
High accuracy
Function flexible

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.

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Application note A150: Smart phone lens mold 4

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

Scanning point measurement


Spiral scan
Probe presented normal, equidistant to the
measurement surface
Probe follows the designed curve while measuring
the distance to the object surface

Non-contact 3D topography measurement for rotational parts


Applications optimized for rotationally symmetric parts; can also handle some complex shapes like
axicon, segmented, annular and asphero-diffractive lenses and slight free form parts
Form measurement accuracy 50 nm (2) over the whole measurement range
Absolute measurement flexible functions
Measurement range ~1.0 mm to ~ 420 mm (diameter)
Maximum slope up to 90 for convex lens and 65 for concave lens
Materials capable of measuring various materials and surface finishes

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Application note A150: Smart phone lens mold 5

Case study
In this note, the measurement method of a LuphoScan system is illustrated using an example of a very
small lens mold measurement.

Characterisation of smart phone camera lens mold


A typical concave aspheric camera lens mold was tested using a LuphoScan system, with
a 2.4 mm clear aperture, 0.5 mm sag and 55 deg maximum slope. The tests were carried
out by applying the Interlignment Module in LuphoScan software. The form error of
the aspheric optical surface and its absolute correlation to the mold rim and mountings
were measured. In addition, its tilt and decenter error (off-axis error) with respect to the
selected mold mounting shaft axis can also be determined in the same software module.

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)

Interface of Interlignment Module Measure decenter (plane A)

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Application note A150: Smart phone lens mold 6

Measurement process of a cell phone lens mold

Measure tilt error and height with the


Measure the aspheric optical surface user defined reference rim

User defined reference plane A User defined reference 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

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Application note A150: Smart phone lens mold 7

Example of measurement results from a lens mold

Aspheric optical surface form measurement results

Position error results

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Application note A150: Smart phone lens mold 8

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.

Some other relevant application notes


Application note A139: Steep-sided miniature aspheres
A139 High precision measurement of steep-sided miniature aspheres
PGI Dimension aspheres

High precision measurement of


steep-sided miniature aspheres

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

characterisation of optical lenses


and manufacture, increasing quality as the slope gets steeper.


Hobsons PGI Dimension addresses these by
yields by over 10%.

A141 Unique measurement capability for steep-sided miniature hemispheres


providing high quality multi-profile data and 3D 2. Alignment The measuring instrument needs
Erik Stover, Business astigmatism analysis. an alignment capability that ensures that each
Development Manager, measurement
Figure 1: Measuring a steep-sided miniature asphere Yang Yu, PhD; Richardis taken right over the aspheric
Smith
Taylor Hobson axis. Simply measuring over an ill-defined turning
Introduction
point on an asphere will yield poor results. The
samples aspheric axis must be truly aligned withApplication note A140: Optical lenses
Traditional spherical optics become heavier lenses required by an optical system and greatly
the instruments rotational axis. This is particularly
and larger as lenses are combined to achieve minimised chromatic and spherical aberration
important if profiles are taken at different angular PGIerrors
and by CCI contact and non-contact techniques
an increase in functionality and precision, means of compensation techniques:
positions. A measurement taken even a few diffractive zones can be adopted to compensate
but in recent years modern optical designs

Advanced contact and


microns off axis, or where the sample is tilted for chromatic aberration arising from the
have employed aspheric and diffractive optics
even slightly, can result in significant measurement refractive properties of the lens.
to reduce the number of lenses needed:
errors. It is therefore critical that the instrument
one aspheric or diffractive lens can replace
alignment
several
and the
result
accuracy
process isspherical
conventional
that weight,
the instrument
repeatable
cost andhas
and stability.
and and
lenses
highused
space
Thecompact
inherent
smaller the
non-contact metrology for
wellas
defined
a
are all
andsample
Key parameters lens form
and roughness

A142 Unique measurement capability for steep-sded small hemispheres


reduced, achieving a more better

characterisation of optical lenses


and the steeper Lens form is one of the most important optical
performing optical the sides the more critical this
system. design parameters used to control the quality of
Figure 2: Common applications of steep-sided becomes.
miniature aspheres Diffractive lenses are normally used by optical precision aspheric and asphero-diffractive optics,
3. Measurement
designers to correct for repeatability As discussed, ensuring they perform as required. In addition,
chromatic aberration Yang Yu, PhD;
surface Richardaffects
roughness Smithperformance. It is
andreliable
aspheric sample
opticsalignment
can be used is necessary
to reducebefore
or
repeatable
eliminate measurements
spherical aberration,can be made.
thereby As we therefore essential to use the very best and most
improving
arequality.
focus dealingDiffractive
with such optics
small samples
provide and
newlowand
Introduction
efficient measurement techniques.
tolerances
powerful this presents
degrees of freedom a significant challenge
for lens design and Traditional spherical optics become heavier lenses required by anApplication
optical system and note A142: Steep-sided small hemispheres
greatly
In this application note we provide some
andinrequires
result the measurement
high quality data from optical system to be and larger as lenses are combined to achieve
systems. minimised chromatic and spherical aberration
examples of the measurement of aspheric and
highly capable and highly stable. Instrument set-up, an asphero-diffractive
increase in functionality PGI Dimension
errors by means of Hemispheres
compensation techniques:
lensesand precision,
using both contact
More recently, the
environment anduse of asphero-diffractive
alignment are very important but(PGI) in recent years modern optical designsand we diffractive zones can be adopted to compensate

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

New software to reduce


2Dthe ever-increasing demandsof


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

set-up time for grinding


special stylus, many measurement systems will
Director, Taylor Hobson Ltd. Dimension in order to demonstrate system
www.taylor-hobson.com
Mobile phone cameras Advanced metrology for optics
Taylor Hobson 2013 accuracy, repeatability and the capability of show a progressive deterioration in data quality
DVD read/write heads as the slope gets steeper.
With the rapid evolution of optics, suitablemeasuring up to 85 degrees
advanced metrology tools areslope.
necessary

and diamond turning


Bar-code scanners

A144 Definitive assessment of radius accuracy and form error


High power LED optics for characterizing lenses with more complex We shapes, of various
also identify somesizes
of and made of
the measurement Alignment The measuring instrument needs
Blu-Ray DVD optics different materials. A number of metrologychallenges tools havefaced
beenwhen employed to measure
measuring the
steep sided an alignment capability that ensures that each
aspheric and asphero-diffractive lenses. Forsamples instance,oncontact stylus profilometry
a profilometer and explainand how
Cameras measurement is taken right over the sample
non-contact interferometry techniques.
Projectors Taylor Hobsons PGI Dimension addresses theseLucy Cooper, Applications Engineer
centre. Simply measuring over an ill-defined
Automotive and medical Phase Grating Interferometry (PGI) is a contact andstylus
provides high quality
profilometry, whichmulti-profile data.
can offer larger turning point may yield poor results. The Application note A144: Camera lenses and moulds

for steep moulds


Head-up displays (HUD) gauge range to resolution when compared with other tradional profilometers, such as
Challenges Introduction
sample must be well aligned to the instruments Survey


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

error for steep moulds


A148 A
 dvanced metrology solutions for small optics
sub-micron form accuracies. diamond turning process.
becomes.
Tim Olsen (Dir. Of
Engineering) Janos Measurement repeatability As discussed,
Technology reliable sample alignment is necessary beforeJunji Kumasa, Asia Applications Manager
repeatable measurements can be made. As Application note A148: Small optics
we are dealing with small samples and low
tolerances this presents a significant challengeIntroduction


and requires the measurement system be highly Coherence Correlation Interferometry (CCI)
The PGI Dimension has Ultra-high precision optical systems and

Advanced metrology solutions


capable and highly stable. Instrument set up,components require measurement of sub-
given us much improved
environment and alignment are very important micron form accuracy and nanometric surface
factors. capability to measure a very finish in order to meet the stringent demands of
Figure 1: METAS Certificate of Calibration No 115-

for small optics


01452. Mean Diameter 9.525453 mm
large range of optics from modern optical technology.
smallturning
Figure 1: Diamond steep spheres
machine to large Figure 2: The fast tool Servo system enables
By use
the of a high precision
diamond turning ofCalibration Referencesuch
surface structures
www.taylor-hobson.com diameter diffractives
Taylor Hobsonand2013Standard, thisprisms,
application
Recent developments at Taylor Hobson have led as micro lens note
arrays,shows how
torics Taylor
and off-axis
to the availability of a gull
newwing aspheres.
Aspheric The
Analysis UtilityHobsons
aspheres PGIwith
Dimension provides
departures todefinitive
upSenior
1000 microns Scientist
(AAU) software Dimension
package. Thisalso
not has
only aprovides Yang Yu, PhD. Applications
very assessment of radius accuracy and form error.
the form error of aspheres
impressive and diffractives,
accuracy and but
also calculates the X-offset and tool radius error Introduction
which are common robust performance,
and frequent problems in the Validation and traceability
giving
diamond turning process. us results we can trust With the increased requirements of cameras, photolithographic alignment Some traditional measurement
To help validate thereducing
PGI Dimension
size andabsolute
weight for many systems and laser surgery. Small Fresnel techniques such as stylus contact
and analysis
reliability we can


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

Laser collimation Optical lens

www.taylor-hobson.com Taylor Hobson 2015

Taylor Hobson UK (Global Headquarters) Taylor Hobson France Taylor Hobson Korea
DiskArt 1988

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