1. Cost estimator tool Zemax | OpticStudio 15
© 2015 Zemax, LLC

2. Welcome to the Webinar! We will discuss
Several design-for-manufacture considerations after optimization and tolerancing
A new XML format for sharing lens data
Cost Estimation with a single lens
Cost Estimation with many lenses

3. Example
We will start with Beam_Expander_Starting_Point.zmx
A typical post-optimization file:

4. Design for Manufacture
Only a few points discussed here:
Use Float-by-Stop, stop on dummy surface
Using manufacturer’s preferred glasses
Define three diameters!
Typically there are only two, we provide three for completeness
Adjust edges for the manufacturing values
Look at thickness/diameter ratios
Generally tidy up parameter data
There is lots more to discuss here, but these are the things we’ll discuss today

5. Glass Choice
Design with whatever you want, but then check the manufacturer’s preferred catalog
Most vendors will work with any mainline glass, but working with preferred glasses is usually a good place to start
Zemax OpticStudio has tools to automate this

6. Glass Choice

7. Tidy data
Should really tidy up radii, thicknesses, semi-diameters to 3 or 3 significant figures at most
I have only done semi-diameters

8. Define Tolerances

9. Zemax Translation

10. Skip the Tolerancing Step!
Tolerancing itself is covered elsewhere, so we won’t cover it here.
Let’s assume that these tolerances give acceptable performance
Move on to providing manufacturing data to the lens vendor
ISO format is an international standard for singlet manufacture
Can be extended to cemented doublets
Everything is really a collection of singlets!

11. ISO 10110 Standard Element Drawing

12. There is more than one diameter!
Semi-diameters and the Draw tab define how lens edges are drawn
ISO plot uses two additional parameters

13. Three diameters
Diameter = 2*LDE(semidiameter)
Effective Diameter is usually the same or smaller, to show a ‘working diameter’
‘Flat’ is the diameter out to the mechanical edge which would include any flat bevel or unpolished surface
Zemax makes good guesses, you may have to refine
Cost Estimator needs ‘Flat Diameter’ to be defined, not set to zero

14. Add ‘Flat’ Diameter

15. That’s a Lot of Data!
XML export is intended to allow all this data to be shared with vendors, without printing and re-keying

16. XML Format
Intended to be an open format for transferring singlet manufacturing data
Includes everything that ISO10110 supports
First use is the ‘Cost Estimator’, which sends this data to a manufacturer for a cost estimate
Optimax have led the way with this

17. First, you have to visit optimaxsci.com to register for a user account
Cost Estimation
First, you have to visit optimaxsci.com to register for a user account
Then tell ZOS what it is

18. Then Set the Quantities

19. Then Look at the Cost Estimator Tab

20. Make Radius Tolerance 2 fringes
Costs go up!

21. Cost Estimator is available from a tab on the ISO drawing
More Cost Estimator
Cost Estimator is available from a tab on the ISO drawing
Useful for studying in-depth the cost impact of tolerance decisions
The Cost Estimator is also available as a standalone tool
Useful for when you have many lenses

22. Cost Estimator Tool

23. Summary
Design for Manufacture requires a lot of attention to detail
The cost estimator is very useful for examining the impact of tolerances on price
It also gives useful error messages related to manufacturability