Recent market demands for free-form optics have challenged the industry to find new methods and techniques to
manufacture free-form optical surfaces with a high level of accuracy and reliability. Production techniques are
becoming a mix of multi-axis single point diamond machining centers or deterministic ultra precision grinding centers
coupled with capable measurement systems to accomplish the task. It has been determined that a complex software tool
is required to seamlessly integrate all aspects of the manufacturing process chain. Advances in computational power and
improved performance of computer controlled precision machinery have driven the use of such software programs to
measure, visualize, analyze, produce and re-validate the 3D free-form design thus making the process of manufacturing
such complex surfaces a viable task. Consolidation of the entire production cycle in a comprehensive software tool that
can interact with all systems in design, production and measurement phase will enable manufacturers to solve these
complex challenges providing improved product quality, simplified processes, and enhanced performance. The work
being presented describes the latest advancements in developing such software package for the entire fabrication
process chain for aspheric and free-form shapes. It applies a rational B-spline based kernel to transform an optical
design in the form of parametrical definition (optical equation), standard CAD format, or a cloud of points to a central
format that drives the simulation. This software tool creates a closed loop for the fabrication process chain. It integrates
surface analysis and compensation, tool path generation, and measurement analysis in one package.
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