Form Error for Individual Stamped Mirrors and Arrays: Precision Optical Manufacturing

はじめに

Ensuring high-precision optical surfaces is essential for beam steering, photonic integration, and fiber coupling applications. The MPC Connector’s micro aspherical mirrors, produced through precision stamping, demonstrate low form error, which contributes to high optical performance. This article examines the form error in individual stamped mirrors and mirror arrays, using Scanning White Light Interferometry (SWLI) for accurate measurement.

 

Key Measurements of Form Error

Using SWLI analysis, the study presents a detailed examination of form error in both individual mirrors and mirror arrays.

Individual Mirror Form Error is defined as the deviations from the reference CAD geometry. With precision stamping, the resulting Individual Mirror Form Error is remarkably low, measured at less than 100nm. This low form error ensures that the mirrors can achieve high precision in beam steering, photonic integration, and fiber coupling applications, maintaining the integrity of the optical path and minimizing aberrations.

On the other hand, Mirror Array Form Error is defined as the deviations in mirror apertures across the entire array. Consistency and uniformity across mirror arrays are essential for applications that rely on multiple optical elements working in concert. The study found that the measured form error for mirror arrays is less than 300nm. Although slightly higher than individual mirrors, this level of precision is still within acceptable limits for high-performance optical systems.

Overall, the use of SWLI for precise measurement of form error in both individual mirrors and mirror arrays highlights the effectiveness of precision stamping techniques in producing high-quality optical components. The low form errors achieved in this study underscores the potential of these manufacturing methods to meet the demanding requirements of modern optical applications.

Statistical Analysis: High-Precision Stamping Results

The precision stamping process was meticulously validated through a comprehensive analysis involving several statistical methods and large sample batches. One of the key methods employed was the Box Plot Analysis of RMS Deviations. This statistical tool was instrumental in assessing the variability and distribution of the form error across multiple samples. It provided a clear visualization of the range, median, and outliers in the data, thereby ensuring that the precision stamping process consistently met high standards of accuracy.

In the study, a substantial batch of 768 individual mirrors was stamped into metallic optical benches. This large sample size enabled a thorough examination of the precision and consistency of the stamping process. Each mirror exhibited minimal form error, reinforcing the efficacy of the precision stamping technique.

Additionally, the study included a batch of 90 mirror arrays, which were measured for uniformity. The uniformity across the mirror arrays is crucial for applications that necessitate multiple optical elements working together harmoniously. The measurements confirmed that the form error across the arrays remained within acceptable limits.

Implications for Optical Performance

These results demonstrate that SENKO’s stamped mirror arrays achieve remarkable precision and uniformity, making them ideal for advanced optical applications. With a sub-100nm form error for single mirrors, SENKO’s products ensure precise light paths remain uncompromised, thereby minimizing aberrations and enhancing overall system performance.

Furthermore, the sub-300nm form error achieved in mirror arrays positions SENKO’s products as highly suitable for Photonic Integrated Circuit (PIC) coupling and Co-Packaged Optics (CPO) applications. The uniformity and precision in these arrays are essential for systems that rely on multiple optical elements working together seamlessly.

In addition to the impressive precision metrics, the repeatability and scalability of SENKO’s high-volume production process are critical for the widespread deployment of Co-Packaged Optics and photonic networks. The ability to repeatedly produce large batches of mirrors and mirror arrays with consistent quality and low form error is vital to support the expanding infrastructure.

 

結論

The impressively low form error in SENKO’s stamped micro aspherical mirrors underscores their exceptional optical quality for high-performance photonic applications. The high-precision stamping process guarantees batch consistency, making these mirrors ideally suited for fiber-to-chip coupling, optical networking, and the integration of next-generation photonic technologies.