Development of a Web-Based e-Portal for Freeform Surfaced Lens Design and Manufacturing and Its Implementation Perspectives

Abstract

In modern freeform surfaced optics manufacturing, ultraprecision machining through single-point diamond turning (SPDT) plays a crucial role due to its ability to meet the high accuracy demands of optical design and stringent surface quality requirements of the final optic. The process involves meticulous steps, including optic surface modeling and analysis, optic design, machining toolpath generation, and manufacturing. This paper presents an integrated approach to customized precision design and the manufacturing of freeform surfaced varifocal lenses through a web-based e-portal. The approach implements an e-portal-driven manufacturing system that seamlessly integrates lens design, modeling and analysis, toolpath generation for ultraprecision machining, mass personalized customization, and service delivery. The e-portal is specifically designed to meet the stringent demands of personalized mass customization, and to offer a highly interactive and transparent experience for the lens users. By using Shiny and R-script programming for platform development and combining COMSOL Multiphysics for the ray tracing simulation, the e-portal leverages open-source technologies to provide manufacturing service agility, responsiveness, and accessibility. Furthermore, the integration of R-script and Shiny programming allows for advanced interactive information processing, which also enables the e-portal-driven manufacturing system to be well suited for personalized complex products such as freeform surfaced lenses.