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Freeform optics has become the most prominent element of the optics industry. Advanced freeform optical designs supplementary to ultra-precision manufacturing and metrology techniques have upgraded the lifestyle, thinking, and observing power of existing humans. Imaginations related to space explorations, portability, accessibility have also witnessed sensible in today’s time with freeform optics. Present-day design methods and fabrications techniques applicable in the development of freeform optics and the market requirements are focussed and explained with the help of traditional and non-traditional optical applications. Over the years, significant research is performed in the emerging field of freeform optics, but no standards are established yet in terms of tolerances and definitions. We critically review the optical design methods for freeform optics considering the image forming and non-image forming applications. Numerous subtractive manufacturing technologies including figure correction methods and metrology have been developed to fabricate extreme modern freeform optics to satisfy the demands of various applications such as space, astronomy, earth science, defence, biomedical, material processing, surveillance, and many more. We described a variety of advanced technologies in manufacturing and metrology for novel freeform optics. Next, we also covered the manufacturing-oriented design scheme for advanced optics. We conclude this review with an outlook on the future of freeform optics design, manufacturing and metrology.

Digital three-dimensional (3D) scanning is a cutting-edge metrology method that can digitally reconstruct surface topography with high precision and accuracy. Such metrology can help traditional manufacturing processes evolve into a smart manufacturing paradigm, which can ensure product quality by automated sensing and control. However, due to limitations with the spatial resolution, scanning speed, and size of the focusing area, commercially available systems cannot be directly used for in-process monitoring in smart manufacturing. For example, a metal 3D printer requires a scanner with second-level sensing, micron-level spatial resolution, and a centimeter-scale scanning region. Among the 3D scanning technologies, structured light 3D scanning can meet the scanning speed criteria but not the spatial resolution and scanning region criteria. This work addresses these challenges by reducing the field of view of a structured light scanner system while increasing the image sensor pixel resolution. Improvements to spatial resolution and accuracy are achieved by establishing hardware selection criteria, integrating the proper hardware, designing a scale-appropriate calibration target, and developing noise reduction procedures during calibration. An additively manufactured Ti-6Al-4V part was used to validate the effectiveness of the proposed 3D scanner. The scanning result shows that both melt pool geometry and overall shape can be clearly captured. In the end, the scanning accuracies of the proposed scanner and a professional-grade commercial scanner are validated with a nanometer-level accuracy white light interferometer using high-density point cloud data. Compared to the commercial scanner, the proposed scanner improves the spatial resolution from 48 to 5 μm and the accuracy from 108.5 to 0.5 μm. Compared to the white light interferometer, the proposed scanner improves the scanning and processing speed from 2 to 20 s.

This paper presents a metrology tool path planning algorithm using an iterative learning-extremum seeking control (ILESC) scheme that combines iterative learning control (ILC) and extremum seeking control (ESC) schemes. In many surface metrology systems, it is inevitable to avoid cosine error that introduces extra uncertainty to the measurement. Cosine error results from the angular misalignment between the measurement probe and the target surface. The proposed ILESC scheme is suitable to address this problem because, unlike the classical control method where the system tracks a given reference signal, ILESC simultaneously compensates for cosine error by simultaneously regenerating the metrology tool path while scanning the target surface, even in case of initial profile unknown. Since no initial geometry profile is given, ESC is deployed to adaptively track the shortest measured distance to the target, which approximately aligns the measurement probe in the perpendicular path to the target. Then, ILC is deployed to each set of measurements to ensure the algorithm converges to an acceptable error threshold given the system’s uncertainty. The proposed scheme was implemented to measure the surface profile of a reference cylinder (ϕ25.4 mm) and freeform lens mold, and the effectiveness of ILESC was evaluated by comparing the measurement results and reference data. As a result, the implemented ILESC scheme showed a 0.32% deviation at full scale.

Test artifacts, resembling real machine parts, allow for quantitative evaluation of system performance and provide insight into individual errors, aiding in improvement and standardization of additive manufacturing. The article provides a comprehensive overview of existing test artifacts, categorized based on geometric features and the material used. Various measurement techniques such as stylus profilometry and computed tomography are employed to assess these artifacts. It is also shown that the selective laser melting (SLM) technology and titanium alloys are prevalent in artifact creation. Specific artifact categories include slits, angular aspects, length parameters, variable surfaces, and others, each accompanied by examples from research literature, highlighting diverse artifact designs and their intended applications. The paper critically discusses the main problems with existing geometries. It underscores the importance of user-friendly and unambiguous artifacts for dimensional control, particularly in surface metrology. Furthermore, it anticipates the continued growth of metrological verification in future manufacturing environments, emphasizing the need for precise and reliable measurement results to support decision-making under production conditions.

The effect of cyclic loading on facture surface topology in notched components made by aluminium alloys is not completely clear. Fractography and fracture mechanics can help to understand this interdependency. This paper aims to study the distribution of the fracture surface roughness of notched 2017A-T4 aluminium alloy after bending fatigue using an optical focus-variation surface measurement technique by applying the fracture zone concept. The effects of stress level at the notch root and the load ratio on fatigue crack growth and fracture surfaces are analysed. Profile and areal surface parameters of four fracture surface regions were investigated at incremental crack lengths of the specimens. Studies have confirmed that the surface areas associated with the main stages of fatigue phenomenon (i.e. crack initiation, crack propagation, and final rupture) have significant differences in roughness which can be explained by the different loading scenarios. Overall, fatigue fracture surfaces have smallest roughness values at the crack initiation stage and a gradual increase during the fatigue crack growth stage.

A relatively new GelSight Max measurement instrument was applied to the microtopographies of experimental hardened clay surfaces, both with and without fingerprint (dermatoglyph) impressions, and the surface of an archaeological pottery handle fragment with a preserved fingerprint (paleodermatoglyph). The experimental clay surfaces were documented in order to determine the instrument’s ability to capture these surfaces in three-dimensions by imprinting them onto an elastomeric tactile membrane. Fingerprints on the experimental hardened clay and the archaeological pottery fragment were mathematically documented to test this instrument’s ability to capture these impressions. The surface texture measurements of the hardened clay and the pottery fragment were mathematically compared using conventional topographic characterization parameters (height and hybrid), fractal dimensions (Das) with associated coefficients of determination (R2), and multiscalar geometric characterization parameters, particularly relative area (Srel), area-scale complexity (Asfc), relative length (RL), and length-scale complexity (Lsfc). The surfaces of the experimental hardened clay with and without fingerprints and the archaeological pottery handle fragment with a fingerprint can be discriminated using some conventional height parameters, as well as some multiscale geometric topographic characterization parameters. Specifically, relative area (Srel), area-scale complexity (Asfc), relative length (RL), and length-scale complexity (Lsfc) could all discriminate between the hardened clay block with and without fingerprints and the fingerprint on the archaeological pottery handle fragment at different scales of measurement. Mean square ratios (MSRs) above 90% and 95% confidence levels indicated that the discrimination of these multiscale geometric characterizations was significant. In sum, the GelSight Max has the potential to be a valuable instrument for archaeologists studying pottery and fingerprints.

Hypertensive crisis (HC) is an emergency health condition which requires an effective management strategy. Over the years, various researchers have developed captopril based fast-dissolving formulations to manage HC; however, primarily, the question of personalisation remains unaddressed. Moreover, commercially these formulations are available as in fixed-dose combinations or strengths, so the titration of dose according to patient’s prerequisite is challenging to achieve. The recent emergence of 3D printing technologies has given pharmaceutical scientists a way forward to develop personalised medicines keeping in view patients individual needs. The current project, therefore, is aimed at addressing the limitations as mentioned above by developing fast-dissolving captopril tablets using 3D printing approach. Captopril unloaded (F1) and loaded (F2-F4) filaments were successfully produced with an acceptable drug loading and mechanical properties. Various captopril formulations (F2–F4) were successfully printed using fused deposition modelling technique. The results revealed that the formulations (F2 and F3) containing superdisintegrant had a faster extent of dissolution and in-vivo findings were endorsing these results. The present study has successfully exhibited the utilisation of additive manufacturing approach to mend the gap of personalisation and manufacturing fast-dissolving captopril 3D printed tablets. The procedure adopted in the present study may be used for the development of fused deposition modelling (FDM) based fast-dissolving 3D printed tablets.

Advanced manufacturing places stringent demands on measurement technologies, requiring ultra-high precision, non-contact operation, high throughput, and real-time adaptability. Optical metrology, with its distinct advantages, has become a key enabler in this context. This paper reviews optical metrology techniques from the perspective of precision manufacturing applications, emphasizing precision positioning and surface topography measurement while noting the limitations of traditional contact-based methods. For positioning, interferometers, optical encoders, and time-of-flight methods enable accurate linear and angular measurements. For surface characterization, techniques such as interferometry, structured light profilometry, and confocal microscopy provide reliable evaluation across scales, from large structures to micro- and nano-scale features. By integrating these approaches, optical metrology is shown to play a central role in bridging macroscopic and nano-scale characterization, supporting both structural assessment and process optimization. This review highlights its essential contribution to advanced manufacturing, and offers a concise reference for future progress in high-precision and intelligent production.

The paper focuses on researching the effect of fatigue loading on metallic structure, lifetime, and fracture surface topographies in AISI H13 steel specimens obtained by selective laser melting (SLM). The topography of the fracture surfaces was measured over their entire area, according to the entire total area method, with an optical three-dimensional surface measurement system. The fatigue results of the SLM 3D printed steel specimens were compared with those reported for conventionally manufactured 13H steel. The investigation also considers the roughness of the specimens’ side surface. Moreover, the fractographic evaluation conducted using scanning electron microscopy confirms that the predominant fracture mechanism is transgranular fracture. Microtomography done after mechanical loading also showed the influence of the stress level on the porosity distribution. Both fractographic and Micro-CT investigations confirm that higher stresses result in coarser and much more uniform porosity observed in fractured samples. These comprehensive quantitative and qualitative fracture analyses are beneficial to predict the failure conditions of SLM steel parts, especially in the case of fatigue damage. From the quantitative analysis of the H13 SLM-manufactured fracture surface topography, it was possible to conclude that the larger the loadings acting on the specimen, the rougher the fracture surface because the ductile fracture mode dominates. It has also been proven that the porosity degree changes along the length of the sample for the most stressed specimens.

In the field of engineering, surface metrology is a valuable tool codified by international standards that enables the quantitative study of small-scale surface features. However, it is not recognized as a resource in the field of cultural heritage. Motivated by this fact, in this work, we demonstrate the use and the usefulness of surface metrology based on scanning conoscopic holography for monitoring treatments on the Venetian masterpiece by Tintoretto St. Martial in Glory with the Saints Peter and Paul. We carried out in situ and in-process monitoring of the painting microtexture during an experimental, innovative laser–chemical treatment, and we performed a statistical analysis based on ISO areal field parameters. A wide and in-band roughness analysis through the complementary use of amplitude, spatial, and hybrid parameters confirmed the noninvasive nature of the whole treatment on the painting surface topography, giving us the chance to review and critically discuss the use of these parameters in a real case in heritage science.