Surface reconstruction and thickness error calculation of optical components with a complex curved surface

The increasing demand for free-form irregular optical components in both military and civilian sectors has made the inspection of such unique shapes a central challenge that hinders their production and use. In particular, the shape and thickness errors of low- and medium-precision components thermally pressed from flat optical materials are greater than those of hard brittle optical components fabricated by subtractive manufacturing, and the resulting impact on human vision is more severe. Reasonable, convenient, efficient, and accurate 3D scanning and data processing for surface reconstruction that combines application scenarios and batch manufacturing needs are urgently needed. Based on the principles of optical ray tracing and triangulation processing, the sampling and calculation of optical path thickness proposed in this paper effectively establish a theoretical model for macroscopic distortion, providing a reasonable solution for distortion correction, batch manufacturing of free-form surface pressing formed components, and defect repair.