Large optical systems fabrication is a demanding task due to the tight requirements and big scales. To make mirrors up to 8.4m in diameter necessitates technological development in materials, tooling, and metrology. These advancements are designed to not only produce optics on a near-unheard of scale, but to improve fabrication methods with each piece.For an optical surface to be properly polished, the amount of material removed during polishing must be greater than the volume of damage left behind by the grinding process. Mixed-mode grinding, which combines bound abrasives with a compliant binder material, is a valuable tool at this stage as it creates less damage while maintaining a fast and uniform cutting rate than traditional loose abrasive grinding.These materials are challenging for large optical surfaces due to the honeycomb structures used to lightweight the mirrors. Development is done to adapt the abrasive to handle the very low pressures and speeds required to avoid imprinting structure on the optical surface.We take a comprehensive approach in measuring mixed-mode behavior using 3M Trizact™. Prior works on bound abrasives have focused on specific properties: removal rates, subsurface damage, etc. None have yet to look at the entire scope of the material and its benefits. These properties will be analyzed along with different behaviors regarding surface scattering, Twyman effect bending moments, glazing, manufacturing expenses, and failure mechanisms. This comprehensive understanding of the abrasive allows manufacturers to create better grinding schedules and reduce overall expenses in fabrication.Trizact shows up to a three times faster removal rate while producing 30\% less subsurface damage than loose abrasives of similar size. Additionally, the surface has scatters less light which can be adapted through changes in processing to create a specular reflection for optical surface metrology.Based on our findings, this type of abrasive integrates into current optical fabrication processes as a pre-polishing material. Here, the transition to these abrasives becomes cost effective by rapidly eliminating damage created during the generating of the surface and reducing the amount of polishing required.

The LSST M1/M3 combines an 8.4 m primary mirror and a 5.1 m tertiary mirror on one glass substrate. The combined mirror was completed at the Richard F. Caris Mirror Lab at the University of Arizona in October 2014. Interferometric measurements show that both mirrors have surface accuracy better than 20 nm rms over their clear apertures, in near-simultaneous tests, and that both mirrors meet their stringent structure function specifications. Acceptance tests showed that the radii of curvature, conic constants, and alignment of the 2 optical axes are within the specified tolerances. The mirror figures are obtained by combining the lab measurements with a model of the telescope's active optics system that uses the 156 support actuators to bend the glass substrate. This correction affects both mirror surfaces simultaneously. We showed that both mirrors have excellent figures and meet their specifications with a single bending of the substrate and correction forces that are well within the allowed magnitude. The interferometers do not resolve some small surface features with high slope errors. We used a new instrument based on deflectometry to measure many of these features with sub-millimeter spatial resolution, and nanometer accuracy for small features, over 12.5 cm apertures. Mirror Lab and LSST staff created synthetic models of both mirrors by combining the interferometric maps and the small high-resolution maps, and used these to show the impact of the small features on images is acceptably small.

The Giant Magellan Telescope (GMT) primary mirror consists of seven 8.4 m light-weight honeycomb mirrors that are being manufactured at the Richard F. Caris Mirror Lab (RFCML), University of Arizona. In order to manufacture the largest and most aspheric astronomical mirrors various high precision fabrication technologies have been developed, researched and implemented at the RFCML. The unique 8.4 m (in mirror diameter) capacity fabrication facilities are fully equipped with large optical generator (LOG), large polishing machine (LPM), stressed lap, rigid conformal lap (RC lap) and their process simulation/optimization intelligence called MATRIX. While the core capability and key manufacturing technologies have been well demonstrated by completing the first GMT off-axis segment, there have been significant hardware and software level improvements in order to improve and enhance the GMT primary mirror manufacturing efficiency. The new and improved manufacturing technology plays a key role to realize GMT, the next generation extremely large telescope enabling new science and discoveries, with high fabrication efficiency and confidence.

Several next generation astronomical telescopes or large optical systems utilize aspheric/freeform optics for creating a segmented optical system. Multiple mirrors can be combined to form a larger optical surface or used as a single surface to avoid obscurations. In this paper, we demonstrate a specific case of the Daniel K. Inouye Solar Telescope (DKIST). This optic is a 4.2 m in diameter off-axis primary mirror using ZERODUR thin substrate, and has been successfully completed in the Optical Engineering and Fabrication Facility (OEFF) at the University of Arizona, in 2016. As the telescope looks at the brightest object in the sky, our own Sun, the primary mirror surface quality meets extreme specifications covering a wide range of spatial frequency errors. In manufacturing the DKIST mirror, metrology systems have been studied, developed and applied to measure low-to-mid-to-high spatial frequency surface shape information in the 4.2 m super-polished optical surface. In this paper, measurements from these systems are converted to Power Spectral Density (PSD) plots and combined in the spatial frequency domain. Results cover 5 orders of magnitude in spatial frequencies and meet or exceed specifications for this large aspheric mirror. Precision manufacturing of the super-polished DKIST mirror enables a new level of solar science.

The Richard F. Caris Mirror Lab at the University of Arizona is responsible for production of the eight 8.4 m segments for the primary mirror of the Giant Magellan Telescope, including one spare off-axis segment. We report on the successful casting of Segment 4, the center segment. Prior to generating the optical surface of Segment 2, we carried out a major upgrade of our 8.4 m Large Optical Generator. The upgrade includes new hardware and software to improve accuracy, safety, reliability and ease of use. We are currently carrying out an upgrade of our 8.4 m polishing machine that includes improved orbital polishing capabilities. We added and modified several components of the optical tests during the manufacture of Segment 1, and we have continued to improve the systems in preparation for Segments 2-8. We completed two projects that were prior commitments before GMT Segment 2: casting and polishing the combined primary and tertiary mirrors for the LSST, and casting and generating a 6.5 m mirror for the Tokyo Atacama Observatory.

Tuberculosis causes more deaths worldwide than any other curable infectious disease. This is the case despite tuberculosis appearing to be on the verge of eradication midway through the last century. Efforts at reversing the spread of tuberculosis have intensified since the early 1990s. Since then, microscopy has been the primary frontline diagnostic. In this dissertation, advances in clinical microscopy towards array microscopy for digital detection of Mycobacterium tuberculosis are presented. Digital array microscopy separates the tasks of microscope operation and pathogen detection and will reduce the specialization needed in order to operate the microscope. Distributing the work and reducing specialization will allow this technology to be deployed at the point of care, taking the front-line diagnostic for tuberculosis from the microscopy center to the community health center. By improving access to microscopy centers, hundreds of thousands of lives can be saved. For this dissertation, a lens was designed that can be manufactured as 4×6 array of microscopes. This lens design is diffraction limited, having less than 0.071 waves of aberration (root mean square) over the entire field of view. A total area imaged onto a full-frame digital image sensor is expected to be 3.94 mm2, which according to tuberculosis microscopy guidelines is more than sufficient for a sensitive diagnosis. The design is tolerant to single point diamond turning manufacturing errors, as found by tolerance analysis and by fabricating a prototype. Diamond micro-milling, a fabrication technique for lens array molds, was applied to plastic plano-concave and plano-convex lens arrays, and found to produce high quality optical surfaces. The micro-milling technique did not prove robust enough to produce bi-convex and meniscus lens arrays in a variety of lens shapes, however, and it required lengthy fabrication times. In order to rapidly prototype new lenses, a new diamond machining technique was developed called 4-axis single point diamond machining. This technique is 2-10x faster than micro-milling, depending on how advanced the micro-milling equipment is. With array microscope fabrication still in development, a single prototype of the lens designed for an array microscope was fabricated using single point diamond turning. The prototype microscope objective was validated in a pre-clinical trial. The prototype was compared with a standard clinical microscope objective in diagnostic tests. High concordance, a Fleiss’s kappa of 0.88, was found between diagnoses made using the prototype and standard microscope objectives and a reference test. With the lens designed and validated and an advanced fabrication process developed, array microscopy technology is advanced to the point where it is feasible to rapidly prototype an array microscope for detection of tuberculosis and translate array microscope from an innovative concept to a device that can save lives.

Aspheric and freeform surfaces are becoming more common as optical designs become more sophisticated and new generations of fabrication tools reduce cost. Unlike spherical surfaces, these surfaces are fabricated with processes that leave a signature or "structure" that is primarily in the mid-spatial frequency region. Tolerancing aspheric and freeform surfaces requires attention to both surface form and structured mid-spatial frequency fabrication errors. These structured surface errors are shown to create image artifacts such as ghosts, and ripples in the MTF profile. Spatial frequencies beyond "form" errors are often ignored or are modeled with statistical descriptors, which do not account for structured errors.This work explores and develops the theory to describe these errors without statistical assumptions. The analytic source of these artifacts in the image Point Spread Function and the Modulation Transfer Function are compared with computational models. The magnitudes of the image artifacts arising from structured surface errors are shown to be non-linear with surface height. It is also shown that multiple structured surface frequencies mix to create sum and difference diffraction orders that are not present in statistical models.An algorithm is developed that enables an optical designer to determine the important spatial frequencies and magnitudes of allowable errors given an MTF performance budget.

The pages of this dissertation detail the development of an advanced metrology instrument for measuring large optical surfaces. The system is designed to accurately guide the fabrication of the Giant Magellan Telescope and future telescopes through loose-abrasive grinding. The instrument couples a commercial laser tracker with an advanced calibration technique and a set of external references to mitigate a number of error sources. The system is also required to work as a verification test for the GMT principal optical interferometric test of the polished mirror segment to corroborate the measurements in several low-order aberrations. A set of system performance goals were developed to ensure that the system will achieve these purposes. The design, analysis, calibration results, and measurement performance of the Laser Tracker Plus system are presented in this dissertation.

Aberrations affect the operation of optical systems, particularly those designed to work at the diffraction limit. These systems include high-resolution microscopes, widely used for imaging in biology and other areas. Similar problems are encountered in photonic engineering, specifically in laser fabrication systems used for the manufacture of fine structures. The work presented in this thesis covers various aspects of adaptive optics developed for applications in microscopes and laser fabrication. By mathematically modelling a range of idealised fluorescent structures, the effect of different aberrations on their intensity in various microscopes is presented. The effect of random aberrations on the contrast of these different structures is then calculated and the results displayed on idealised images. Images from a two-photon microscope demonstrate the predicted results. The contrast of two structures is compared when imaged first by a conventional microscope and then by the two-photon or confocal sectioning microscopes. The different specimen structures were seen to be affected to varying extents by each aberration mode. In order to correct for aberrations in microscopy and other photonic applications, adaptive elements such as deformable mirrors are incorporated into the optical setups. An important step is to train the deformable mirror so that it produces appropriate mode shapes to apply a phase to optical wavefronts. One such mirror is modelled using the membrane equation to predict the surface shape when an actuator is applied. Each of these influence functions is combined to produce a set of orthogonal mirror modes, which are used to experimentally produce a set of empirical modes in a two-photon microscope. An alternative method of training a deformable mirror from a spatial light modulator is employed. The focal spot of an optical system is imaged to provide a feedback metric for the mirror to replicate the phase pattern on the spatial light modulator. A two-photon microscope with adaptive optics is demonstrated by imaging the brains of Drosophila deep within the bulk, correcting for both system and specimen induced aberrations using the deformable mirror with empirical mirror modes applied. A harmonic generation microscope is also used to image both biological and non-biological specimens whilst performing aberration correction with a deformable mirror. Adaptive optical methods are also applied to a laser fabrication system, by constructing a dual adaptive optics setup to correct for aberrations induced when fabricating deep in the bulk of a substrate. The efficiency and fidelity of fabrication in diamond substrate is shown to be significantly increased as a result of the dual aberration correction. An outstanding problem in microscopy is the effect of spatially variant aberrations. Using measurements from the adaptive microscopes, the extent to which they are present in a range of specimens is quantified. One potential technique to be used to correct for these aberrations is multi-conjugate adaptive optics. Different configurations of a multi-conjugate adaptive optics system are modelled and the improvement on the Strehl ratio of aberrated images quantified for both simulated images and real data. The application of this technique in experimental microscopes is considered.

La prochaine décennie instrumentale en astronomie se veut extrême. Elle s’ouvre avec l'arrivée des ELTs (Extremely Large Telescopes). Leur miroir primaire géant permettra d'augmenter considérablement la quantité de flux collectée et d'améliorer la résolution angulaire, paramètres clés pour l'observation et l'imagerie de sources astrophysiques. Des conséquences directes sont l'augmentation de la complexité, de l'envergure et de la masse des instruments placés aux foyers de ces télescopes. Une solution passe par l'utilisation de miroirs de formes libres. Or aujourd’hui, obtenir ces formes exotiques via les méthodes traditionnelles de fabrication optique n’est pas possible et un appel à de nouvelles ruptures technologiques s'avère nécessaire. Cette thèse présente un travail de recherche et développement amont portant sur un procédé de fabrication innovant permettant de fournir des miroirs de formes libres, avec les performances optiques requises en observations visibles et infrarouges. Ce procédé est une évolution des techniques d'Optique Active et exploite la déformation plastique des matériaux métalliques. Cependant, le domaine plastique reste un domaine de comportements non-linéaires analytiquement complexes. Il est alors d'intérêt de comparer des modèles par éléments finis avec des essais réels. Ces derniers ont nécessité la mise en place de la gamme complète de fabrication des substrats et des moyens d’essais. Les premiers miroirs obtenus pourront mettre en évidence les paramètres principaux à prendre en compte ainsi que leur niveau de sensibilité, pour ensuite converger vers des modèles éléments finis fiables et une solution de fabrication optique maîtrisée. / The next instrumental decade in astronomy aims to be extreme. It opens with the arrival of ELTs (Extremely Large Telescopes). Their giant primary mirrors will increase the light collecting power and the angular resolution, key parameters for observing and imaging of celestial bodies. However, this also leads to an increase in the complexity, size and weight of their focal-plane instruments, to minimize flux lost and to correct for the aberrations introduced. A solution would be to implement freeform mirrors inside the optical systems of these instruments. Today, it is not possible to obtain these exotic mirror shapes using the current optical fabrication techniques and new technological breakthroughs in this domain are essential. This PhD thesis present research and development work, in upstream phase, of an innovative manufacturing process to supply freeform mirrors, which should meet required optical performances in Visible and Infrared wavelength astronomical observations. This method is an evolution of Active Optics techniques and based on the ability of metallic materials to plasticize. However, the plasticity of metallic materials remains a field of non-linear behaviours and analytically complex. It is important to compare modeling from finite element analysis and real tests. For these tests, the complete manufacturing steps of the metallic substrates were put in place. The first mirrors obtained will highlight the main working parameters and their sensibility levels, and then converge toward reliable finite elements models and a mastered solution of optical freeform mirrors fabrication.