Translating optical design specifications into manufacturing terminology: bridging the gap between designers and manufacturers

Bridging the communication gap between optical designers and manufacturers is essential to ensure optical systems meet performance, cost, and production requirements. Design specifications often rely on terminology and parameters that are not immediately applicable in manufacturing, creating challenges for collaboration. This paper presents a framework for translating optical design data into manufacturing-relevant terms, fostering a shared understanding between these worlds. The Export to PanDao tool in Ansys Zemax OpticStudio facilitates this translation by converting critical optical parameters - such as surface shapes, tolerances, and mechanical dimensions - into an intermediary .JSON data format aligned with fabrication practices. For example, edge diameter, tilt, decenter, and asphericity are expressed in ways that reflect practical manufacturing considerations. Tolerances on curvature, thickness, and irregularity are similarly redefined into metrics suited for production validation, such as fringe-based or RMS irregularity measures. By standardizing this data exchange, optical designers and manufacturers can collaborate more effectively, reducing misunderstandings and ensuring that design intent translates seamlessly into manufacturable components. This approach improves efficiency and reliability throughout the development process.