Compensated differential Zernike fitting method for wavefront aberration metrology based on grating lateral shearing

Lateral shearing based on the grating is one of the classical configurations when measuring the wavefront aberration of optical systems such as the lithographic projection lens. Because the wavefront under test is spherical, but a detector surface is a plane, the coordinate of the wavefront surface will be distorted on the detector surface. As the numerical aperture (NA) of the optics under test increases, the shear ratios at different positions within the shearing region are significantly different due to the coordinate distortion. Therefore, the reconstructed wavefront from the traditional lateral-shearing reconstruction method designed for a fixed shearing ratio will contain a non-negligible error. In this work, we use the ray-tracing method to calculate the shearing ratio distribution in the shearing region and propose a compensated differential Zernike fitting method to solve the coordinate distortion and shearing ratio variation problem. The relative error of the uncompensated result will increase as the NA increases. This error is around 1% for a 0.1 NA, 10% for a 0.3 NA, and over 100% for an NA above 0.7. Compensation for the shearing ratio variation is necessary when the NA is larger than 0.3. The proposed method has been validated by simulations and experiments.