Customized design and efficient fabrication of two freeform aluminum mirrors by single point diamond turning technique

The precision single point diamond turning technique has been a promising technology for generating small and medium-sized freeform optical elements with high surface quality. In this paper, we present an extremely off-axis freeform optical system with a large 10.0 mm pupil diameter and a low 3.0 F-number over a wide 28° field of view. It is composed of two freeform aluminum mirrors, which are fabricated efficiently by the single point diamond turning machine. The manufacturing strategy and parameters are estimated rationally and comprehensively, based on the freeform surface characters. The freeform aluminum mirror surface can reach submicron surface accuracy and achieve nanometer surface roughness. The final assembled prototype of the off-axis two-mirror freeform display optical system has the advantages of compactness, a broad spectrum, and good display imaging performance.