Fabrication of hybrid optical structure by direct machining

A Moore 350FG 5-axis ultra precision machine tool platform with diamond tooling was used to generate v-shaped diffractive pattern on a refractive sinusoidal shaped structure. The refractive surface behaves like a cylindrical lens and the diffraction grating stretches the line focuses generated by the refractive surface. The structure was machined on an electroless nickel insert. The design and the simulation of the hybrid structure were performed using ray tracing and exact electromagnetic theory. The response of the grating was calculated by using Fourier modal method and the data was used in ZEMAX to calculate the amplitude and the phase of the diffracted rays.