Genetic algorithm-powered non-sequential dwell time optimization for large optics fabrication

Computer Controlled Optical Surfacing (CCOS) is widely applied for fabricating large aspheric optical surfaces. For large optics fabrication, various sizes of polishing tools are used sequentially. This raises the importance of efficient and globally optimized dwell time map of each tool. In this study, we propose a GEnetic Algorithm-powered Non-Sequential (GEANS) optimization technique to improve the feasibility of the conventional non-sequential optimization technique. GEANS consists of two interdependent parts: i) compose an influence matrix by imposing constraints on adjacent dwell points and ii) induce the desired dwell time map through the genetic algorithm. CCOS simulation results show that GEANS generates a preferable dwell time map that provides high figuring efficiency and structural similarity with the shape of target removal map, while improving computational efficiency more than 1000 times over the conventional non-sequential optimization method. The practicability of GEANS is demonstrated through error analyses. Random tool positioning error and tool influence function errors are imposed on dwell time maps. Compared to the conventional non-sequential optimization method, the power spectral density values of residual surface error from GEANS remain stable. GEANS also shows superior applicability when the maximum acceleration of a tool is applied.