Single-point diamond turning and replication of visible and near-infrared diffractive optical elements.

High-fidelity diffractive surfaces have been generated with single-point diamond-turning techniques. A key to the success of this technique is the ability to shape the diamond tool tip to provide the optimum phase-relief profile, given manufacturing constraints. Replication technology is used to transfer the phase-relief surface into a thin epoxy or photopolymer layer on a glass substrate. Diffraction efficiency results for a wide range of zone widths are presented to provide the reader with a baseline of expected performance for replicated visible and near-infrared diffractive optical elements. In addition, a new method for analyzing diffractive surface structures is presented. The ray-trace algorithm quickly provides accurate results of predicted diffraction efficiency for arbitrary zone profiles, which is extremely valuable in predicting manufacturing errors.