Convex optical freeforms using fringe Zernike overlay approach for two-mirror and three-mirror telescopes for space applications

The challenge in manufacturing and testing of convex optical parts is well known in comparison to its concave counterpart and an optimized imaging system invariably features a combination of both. Of late, freeform mirrors find lot of interest in space applications as the optical systems remain compact within the allocated envelope. As is well known, these freeform mirrors are difficult to manufacture and test due to their lack of rotational or translational symmetry and poses additional challenges if it has convex profile. In the current investigations, two new convex freeform optical surfaces are proposed which is based on fringe Zernike overlay technique. The first convex freeform envisaged is for a two-mirror off-axis telescope where the secondary mirror is an off-axis freeform and the second convex freeform for a three-mirror anastigmat telescope where the secondary mirror is an on-axis convex freeform. Substitution of these convex freeform surfaces in the two-mirror and three-mirror telescope systems aid in the correction of asymmetrical aberrations to a wider view field, thereby enhancing the performances of the de-centred and tilted systems in the respective configurations. The procedure adopted for the manufacturing of these convex freeform surfaces using bonnet polishing methods and the interferometric tests using modified-Hindle null corrector and subaperture-stitching techniques for evaluation are described in detail. •Convex freeform surfaces fabrication and testing.•Detailed method of fabrication of freeform surface to achieve 15 nm RMS error against required freeform surface accuracy.•Interferometric testing of the surfaces using a modified Hindle sphere test and sub-aperture stitching methods.