In the last 10 years, freeform optics has enabled compact and high-performance imaging systems. This article begins with a brief history of freeform optics, focusing on imaging systems, including marketplace emergence. The development of this technology is motivated by the clear opportunity to enable science across a wide range of applications, spanning from extreme ultraviolet lithography to space optics. Next, we define freeform optics and discuss concurrent engineering that brings together design, fabrication, testing, and assembly into one process. We then lay out the foundations of the aberration theory for freeform optics and emerging design methodologies. We describe fabrication methods, emphasizing deterministic computer numerical control grinding, polishing, and diamond machining. Next, we consider mid-spatial frequency errors that inherently result from freeform fabrication techniques. We realize that metrologies of freeform optics are simultaneously sparse in their existence but diverse in their potential. Thus, we focus on metrology techniques demonstrated for the measurement of freeform optics. We conclude this review with an outlook on the future of freeform optics.

A miniature imager is demonstrated using a metaform—a rotationally variant optic with an integrated metasurface.

We recently reported on an Optical Coherence Microscopy technique, whose innovation intrinsically builds on a recently reported - 2 µm invariant lateral resolution by design throughout a 2 mm cubic full-field of view - liquid-lens-based dynamic focusing optical probe [Murali et al., Optics Letters 34, 145-147, 2009]. We shall report in this paper on the image acquisition enabled by this optical probe when combined with an automatic data fusion method developed and described here to produce an in-focus high resolution image throughout the imaging depth of the sample. An African frog tadpole (Xenopus laevis) was imaged with the novel probe and the Gabor-based fusion technique, demonstrating subcellular resolution in a 0.5 mm (lateral) x 0.5 mm (axial) without the need, for the first time, for x-y translation stages, depth scanning, high-cost adaptive optics, or manual intervention. In vivo images of human skin are also presented.

A 60-deg-field-of-view optical see-through head-mounted display (HMD) using off-axis optics has been designed for 3-D medical imaging visualization. Two basic on-axis optical design concepts for see-though HMDs are reviewed first, to motivate the design of an off-axis optical form. An off-axis design is then presented. Because HMDs are typically designed from the pupil of the eye to the miniature display, it is common to assess final performance according to the display characteristics. Such analysis, however, does not provide information that is easily translated into task-based performance metric. Therefore, we present an analysis of the performance of the design from a usability viewpoint. For this analysis, the optical system is ray-traced from the display to the eye. Three key measures of performance—accommodation, astigmatism, and chromatic blur—are presented over the field of regard using customized graphical output. © 2000 Society of Photo-Optical Instrumentation Engineers.

A freeform pushbroom hyperspectral imager design was investigated as a combination of a freeform reflective triplet imager and a freeform reflective triplet spectrometer used in double-pass. The design operates at about F/2 with a 15-degree cross-track field-of-view and a 30 mm entrance pupil diameter. The design process led to achieving a small volume of less than 2 liters that fits comfortably within a 3U CubeSat geometry, exemplifying the compactness of this hyperspectral imager. We report the freeform sag departures and maximum slopes of the freeform surfaces, as well as the manufacturing tolerances together with an evaluation of the system stray light, all of which highlight the feasibility of a design in this class to be manufactured. This design uniquely positions itself on the landscape of compact hyperspectral imagers.

Gradient Refractive INdex (GRIN) optical components have historically fallen short of theoretical expectations. A recent breakthrough is the manufacturing of nanolayered spherical GRIN (S-GRIN) polymer optical elements, where the construction method yields refractive index gradients that exceed 0.08. Here we report on the application of optical coherence tomography (OCT), including micron-class axial and lateral resolution advances, as effective, innovative methods for performing nondestructive diagnostic metrology on S-GRIN. We show that OCT can be used to visualize and quantify characteristics of the material throughout the manufacturing process. Specifically, internal film structure may be revealed and data are processed to extract sub-surface profiles of each internal film of the material to quantify 3D film thickness and homogeneity. The technique provides direct feedback into the fabrication process directed at optimizing the quality of the nanolayered S-GRIN polymer optical components.