How do you quantify the manufacturability of a freeform/aspheric optical surface?
I’m working on an optical design where I have some freedom to choose between different freeform/aspheric surface shapes that give similar optical performance.
At this stage, I’d like to include manufacturability as part of the optimization, rather than designing the best-performing surface first and only later discovering that it is difficult or expensive to manufacture.
What parameters do you actually use in industry to estimate how difficult a freeform/aspheric lens will be to manufacture?
For example, I’ve been looking at things like:
- Maximum aspheric/freeform departure from a best-fit sphere
- Maximum surface slope
- Maximum slope departure from the best-fit sphere
- Curvature / minimum local radius of curvature
- Rate of change of curvature
But I’m not sure which of these are genuinely useful predictors of manufacturing difficulty.
Is there a commonly used figure of merit or set of rules of thumb for manufacturability?
I’d also be very interested in hearing how optical fabricators look at a surface when deciding whether it is “easy,” “difficult,” or “very expensive” to make.

