Design and tolerance of a free-form optical system for an optical see-through multi-focal-plane display

Xinda Hu; Hong Hua

doi:10.1364/AO.54.009990

Applied Optics
Vol. 54,
Issue 33,
pp. 9990-9999
(2015)
•https://doi.org/10.1364/AO.54.009990

Design and tolerance of a free-form optical system for an optical see-through multi-focal-plane display

Xinda Hu and Hong Hua

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Xinda Hu and Hong Hua, "Design and tolerance of a free-form optical system for an optical see-through multi-focal-plane display," Appl. Opt. 54, 9990-9999 (2015)

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Table of Contents Category
- Optical Design and Fabrication
Optics & Photonics Topics
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The topics in this list come from the Optics and Photonics Topics applied to this article.

About this Article
History
- Original Manuscript: August 6, 2015
- Revised Manuscript: October 13, 2015
- Manuscript Accepted: October 26, 2015
- Published: November 20, 2015

Abstract

By elegantly combining recent advancements of free-form optical technology and multi-focal-plane (MFP) display technology, we developed a high-performance true 3D augmented reality (AR) display that is capable of rendering a large volume of 3D scenes with accurate focus cues; this display overcomes the accommodation-convergence discrepancy problem in conventional AR display. In this paper, we concentrate on various aspects of engineering challenges in the design and integration of a free-form optical see-through eyepiece with MFP technology for our AR display prototype. We present the design and optimization strategy in coupling free-form optics with a rotational-symmetric lens system to achieve high image quality. A comprehensive tolerance analysis of this complicated optical system is also presented, including an effective tolerance method for random surface figure errors on aspheric and free-form surfaces. Finally, the image quality of the virtual display is evaluated, which shows the as-built performance matches very well with the optical design results and tolerance analysis.

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Virtual Display Path
Microdisplay	0.7” DMD,(XGA resolution, 14 μm pixel)
Wavelengths	Visible (465 nm, 525 nm, 635 nm)
Deformable mirror defocus range	0–1.2 diopters (10 mm aperture)
Focal-plane tunable range	0–3.0 diopters
Display field of view	Constant 40° ( $32.5 ° H \times 24.5 ° V$ )
Free-form eyepiece EFL	27.5 mm
Exit pupil diameter	6.3 mm
Eye clearance	25 mm (low profile glasses)
Image quality	Polychromatic $MTF > 0.2$ at 35 cycles/mm (3 mm pupil)
Distortion	$< 5.0 %$
Optical See-Through Path
See-through field of view	60° ( $50 ° H \times 45 ° V$ )
Pupil diameter	10 mm
See-through quality	Polychromatic $MTF > 0.4$ at 30 cycles/deg (3 mm pupil, FOV 40°)
See-through distortion	$< 2.0 %$ (FOV 40°)

Tolerance Type	Value	Tolerance Class [29]
Free-form Eyepiece
Figure accuracy (user-defined)	$\pm 2 um$
Surface decenter (DLX, DLY, DLZ)	$\pm 25 um$	Select
Surface tilt (DLA, DLB, DLG)	$\pm 10 mrad$	Select
Material(Index DLN, V-number DLV)	$\pm 0.001$ , $\pm 0.8 %$	Regular
Refractive-Diffractive Field Lens
Figure accuracy (user-defined)	$\pm 2 um$
Surface decenter (DEC)	$\pm 25 um$	Select
Surface tilt (TIL)	$\pm 10 mrad$	Select
Thickness (DLT)	$\pm 50 um$	Select
Material(Index DLN, V-number DLV)	$\pm 0.001$ , $\pm 0.8 %$	Regular
DOE blaze depth error (User-defined)	$\pm 5 %$

Tolerance Type	Tolerance Value	Affected Fields	Worst MTF Value Drop
Deformation S3—Figure accuracy	$\pm 2 μm$	All	−0.023
DLZ S2—Surface Z-displacement	$\pm 25 μm$	F10, F11	−0.018
DLY S3—Surface Y-displacement	$\pm 25 μm$	F2, F3, F10, F11	−0.017
DLZ S3—Surface Z-displacement	$\pm 25 μm$	F10, F11	−0.017
Deformation S2—Figure accuracy	$\pm 2 μm$	All	−0.015
DLY S2—Surface Y-displacement	$\pm 25 μm$	F2, F3, F10, F11	−0.014
DLX S2—Surface X-displacement	$\pm 25 μm$	F10, F11	−0.012
DLX S3—Surface X-displacement	$\pm 25 μm$	F10, F11	−0.01

Monte Carlo Analysis −3000 Trials Cumulative Probability Change of MTF at 28 Cycles/mm
Field	50.00%	84.10%	97.70%	99.90%
1	−0.0002	−0.0149	−0.0249	−0.0421
2	0.0003	−0.0159	−0.0329	−0.0533
3	−0.0001	−0.0164	−0.0336	−0.0535
4	0.0010	−0.0130	−0.0206	−0.0374
5	0.0003	−0.0139	−0.0216	−0.0384
6	0.0013	−0.0115	−0.0206	−0.0367
7	0.0000	−0.0130	−0.0214	−0.0374
8	−0.0018	−0.0145	−0.0272	−0.0439
9	0.0012	−0.0120	−0.0197	−0.0277
10	−0.0025	−0.0232	−0.0475	−0.0709
11	−0.0022	−0.0228	−0.0459	−0.0697
12	−0.0025	−0.0088	−0.0166	−0.0279
13	−0.0022	−0.0084	−0.0133	−0.0273

Virtual Display Path
Microdisplay	0.7” DMD,(XGA resolution, 14 μm pixel)
Wavelengths	Visible (465 nm, 525 nm, 635 nm)
Deformable mirror defocus range	0–1.2 diopters (10 mm aperture)
Focal-plane tunable range	0–3.0 diopters
Display field of view	Constant 40° ( $32.5 ° H \times 24.5 ° V$ )
Free-form eyepiece EFL	27.5 mm
Exit pupil diameter	6.3 mm
Eye clearance	25 mm (low profile glasses)
Image quality	Polychromatic $MTF > 0.2$ at 35 cycles/mm (3 mm pupil)
Distortion	$< 5.0 %$
Optical See-Through Path
See-through field of view	60° ( $50 ° H \times 45 ° V$ )
Pupil diameter	10 mm
See-through quality	Polychromatic $MTF > 0.4$ at 30 cycles/deg (3 mm pupil, FOV 40°)
See-through distortion	$< 2.0 %$ (FOV 40°)

Abstract

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Tables (4)

Equations (1)

Applied Optics