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The growing interest in providing additional degrees of freedom to the design of high-end optical systems has led to an increased demand for freeform optical elements. The efficient fabrication of such elements requires a polishing process that provides high removal rates and a stable removal function while working with a relatively small spot size. Taking these constraints into consideration this paper focuses on the successful implementation of polishing processes applying the A-WPT (Advanced Wheel Polishing Tool) technology. In order to maintain perpendicularity towards the freeform surface to be polished, the A-WPT is run on a 6-axis machining system with an optimized kinematics set-up. Herein the use of a tip-tilt unit successfully suppresses the formation of singularities, e.g. close to the surface vortex when polishing along a raster tool path. First results for the pre-polishing of an off-axis parabolic surface made of Zerodur are analyzed and discussed.
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Sebastian Stoebenau, Rafael Hild, "Optimized kinematics for efficient freeform polishing," Proc. SPIE PC12778, Optifab 2023, PC1277803 (30 November 2023); https://doi.org/10.1117/12.2691549