Tutorial 6: How to get real-time lens prototype costs in OpticsViewer

Design for manufacture is a phrase commonly used to describe how manufacturing considerations are incorporated into the optical design process. OpticsViewer offers several capabilities that support design for manufacture, and the Cost Estimator takes the concept to new heights by allowing users to get real-time cost estimates direct from manufacturers. This tool uses an XML file, generated from data in the ISO 10110 drawing to ensure a seamless data exchange.

Authored By Alina Shmidt

Downloads

Article Attachments

Introduction

OpticsViewer offers several capabilities that support design for manufacture, and the Cost Estimator takes the concept to new heights. The tool allows you to send lens data to manufacturers and get real-time cost estimates. The designer can then see the cost impact of lens shape, size, material, coatings, quality and quantity. This capability is unprecedented in the optical design software industry.

This article will provide a tutorial on how to use the Cost Estimator tool. 

Registering with manufacturers

Prior to using the Cost Estimator, users must register with the supported manufacturer. Below you will find instructions on registering with supported manufacturers.

Optimax

For a complete description of usage of the Optimax estimator, please refer to the documentation available for download in the Article Attachments section above. Please note that while the attachment is written for OpticStudio users, its content still applies to OpticsViewer users.

Go to the website for the Optimax Estimator here and click the link to register. 

Once you have registered with the desired manufacturer, open OpticsViewer and click Manage Providers in the Cost Estimator section of the System Explorer. Click on the desired provider and enter your username and password provided by the vendor. After closing the dialog, the information will be saved and the estimator will be ready to use.

Manage Providers

Password information can be saved in an encrypted format using the Export Provider Data button in the System Explorer. Later, when the password needs to be reloaded, it can be imported using the Import Provider Data button.

Using the Cost Estimator

The Cost Estimator can be found in two locations in OpticsViewer. It can be launched from the Manufacture drop-down or from the dedicated tab in the ISO Element Drawing:

Cost Estimator

ISO Drawing Cost Estimates Tab

The tool requires several pieces of information provided in the ISO 10110 drawing in order to provide cost estimates. The lens shape, size, material, coatings, and quality (tolerances) are all needed. Tolerances should be pulled in from the tolerance data editor by clicking Reset from TDE button in the Setttings...General tab. Please note that not all settings in the ISO inputs are considered for cost estimation; the inputs utilized in cost estimation vary depending on the providor used. See below for providor-specific information. Once all this information is in the ISO 10110 drawing, the user can proceed to define the settings for the estimator.

Optimax Cost Estimator supported parameters

When using Optimax as the Cost Estimator, the following fields (highlighted in the images below) are considered:

Fields Considered For Optimax

Fields Considered for Optimax

Fields Considered for Optimax

The definitions of the Diameter inputs in the first image above are as follows: 

  • Effective Diameter: This is the clear aperture for the surface (area over which form and cosmetic tolerances must be met).
  • Diameter: This is the effective diameter plus the chip zone (over which the surface form continues). For concave surfaces, it is also called the opening.
  • Diameter (flat): This is the overall finished part diameter. For concave surfaces, it is the diameter of the opening plus the flat area (sag face). For convex surfaces, the diameter and diameter (flat) are usually the same value.

Diameter Definitions

Generating the Cost Estimate

When opening the Cost Estimator from the ISO 10110 drawing, the currently configured lens will be used for cost estimates. The user defines the manufacturer and quantities they would like estimates for. Multiple quantities can be quoted simultaneously by using commas to separate them.

Cost Estimation Per Quantity

Once the settings are defined properly, click OK and the estimator will obtain estimates from the selected providers. If the unit costs are returned as zero, check the messages for errors in the lens data sent.

The Cost Estimator launched from the Manufacture drop-down offers similar functionality with a few more options. This tool loads lens data from an XML file (generated by the ISO 10110 drawing) or directly from a ZMX file. Alternately the user can create a new part directly within the tool by entering the lens data manually. Multiple lenses can be loaded simultaneously. Selecting a specific part from the list at the top of the tool will list its surface and material data in the center of the dialog. Cost estimates are provided at the bottom of the dialog after pressing Refresh Estimates.

Cost Estimator From Tolerance Tab

Vendor limitations and information

Cost estimate providers have some limitations in the values that can be used, in either the lens prescription, cost estimator settings, or tolerances. Some of the limitations and other pertinent informations for currently supported providers are provided below. 

Optimax

Please refer to the Optimax Cost Estimator documentation, provided as an article attachment, for a full set of information. This is a useful tool for understanding how lens properties affect the estimates returned. Please note that while the attachment is written for OpticStudio users, its content still applies to OpticsViewer users.

The Estimator is designed around prototype optics that Optimax can deliver in 1 week, and is thus limited in scope to a set of boundary conditions. For example, the glasses used in the lens prescription must be from OpticsViewer's default OPTIMAX glass catalog. Another example is that there are minimum values allowed on tolerance inputs (precision limitations). For a complete set of cost estimate boundary conditions, please refer to the Optimax Cost Estimator Documentation. Please note that the actual full scope of manufacturing capabilities at Optimax are much broader. 

When using Optimax as the provider, error messages will be returned if the data submitted violates any of the above limitations. Those error codes are listed below.

001

The submitted XML File has transmission errors. Please resubmit or contact Zemax customer service.

002

Missing part side.

003

Invalid surface type on Left Surface. Only Standard and Even Aspheres are supported at this time.

004

Invalid surface type on Right Surface. Only Standard and Even Aspheres are supported at this time.

100

Log In failed. To register for the Optimax Estimator go to estimator.optimaxsi.com and click Register.

101

Your Estimator account has expired. To renew contact estimator@optimaxsi.com

110

Quantity must be between 1 and 10 for estimates.

111

Radius must be between 10mm and 1500mm.

112

Edge Thickness at diameter (flat) must be 1mm or greater.

113

Left Surface: R/numbers faster than R/1 are not supported.

114

Right Surface: R/numbers faster than R/1 are not supported.

115

Left surface is plano and 3/A must be more than 1fr for Optimax Cost Estimates.

116

Right surface is plano and 3/A must be more than 1fr for Optimax Cost Estimates.

117

Left Surface: Form Error 3/B is required for Optimax Cost Estimates.

118

Right Surface: Form Error 3/B is required for Optimax Cost Estimates.

119

Left Surface: Form Error 3/C is not supported in Optimax Cost Estimates.

120

Right Surface: Form Error 3/C is not supported in Optimax Cost Estimates.

121

Left Surface: RMS values for Form Error are not considered in Optimax Cost Estimates.

122

Right Surface: RMS values for Form Error are not considered in Optimax Cost Estimates.

123

Left surface is plano and must have power set for Optimax Cost Estimates.

124

Right surface is plano and must have power set for Optimax Cost Estimates.

125

Left Surface: Must have either radius or a power or both for Optimax Cost Estimates.

126

Right Surface: Must have either radius or a power or both for Optimax Cost Estimates.

127

Left surface: Conic Constant tolerances are not considered in Optimax Cost Estimates.

128

Right surface: Conic Constant tolerances are not considered in Optimax Cost Estimates.

200

The material that you have specified is not an Optimax Preferred Glass. Optimax processes most optical materials. Please contact a Sales Engineer.

201

Left Surface: The coating that you have specified is not an Optimax Coating. Please select an Optimax coating from the catalog.

202

Right Surface: The coating that you have specified is not an Optimax Coating. Please select an Optimax coating from the catalog.

203

Lens thickness is greater than standard glass strip thickness as supplied by glass manufacturer.

204

Lens width greater than glass strip width as supplied by glass manufacturer.

300

Material Thickness must be between 2mm and 100mm.

301

Material Thickness tolerance must be 0.05mm or greater total.

302

Left Surface: ISO Grade Number (5/A) must be greater or equal to 0.063

303

Right Surface: ISO Grade Number (5/A) must be greater or equal to 0.063

304

Left Surface: ISO Surface Imperfection (5/L_A'') must be greater than or equal to 0.001

305

Right Surface: ISO Surface Imperfection  (5/L_A'') must be greater than or equal to 0.001

306

Left Surface: Clear Aperture cannot be greater than 90% of the diameter (flat).

307

Right Surface: Clear Aperture cannot be greater than 90% of the diameter (flat).

308

Left Surface: Clear Aperture cannot be greater than 90% of the diameter (opening).

309

Right Surface: Clear Aperture cannot be greater than 90% of the diameter (opening).

310

Left Surface: Diameter (opening) cannot be larger than Diameter (flat).

311

Right Surface: Diameter (opening) cannot be larger than Diameter (flat).

312

Left Surface: Diameter (opening) cannot be less than Clear Aperture.

313

Right Surface: Diameter (opening) cannot be more than Clear Aperture.

314

Diameter (flat) with tolerances should be between {minimum-value} mm and 100mm.

315

The Material Thickness to Diameter (flat) aspect ratio should not be less than 1/5th of the Diameter (flat) and not more than 10 times the Diameter (flat).

316

Diameter (flat) tolerance must be 0.015mm or greater total.

317

Left Surface: The Diameter tolerance converts to a sag tolerance that is too small to measure (limit is +/-0.015 mm).

318

Right Surface: The Diameter tolerance converts to a sag tolerance that is too small to measure (limit is +/-0.015 mm).

319

Left Surface: Power Tolerance must be 1 fringe or greater.

320

Right Surface: Power Tolerance must be 1 fringe or greater.

321

Left Surface: Form Tolerance B should be no less than 0.2 fringes.

322

Right Surface: Form Tolerance B should be no less than 0.2 fringes.

323

The calculated Edge Thickness Difference tolerance is too small for the Cost Estimator.  Must be 0.005mm or greater. Please revise lens attributes or contact sales@optimaxsi.com for more information.

324

The RMS Roughness must be 10 Angstroms or greater.

325

{Side} aspheric surface: minimum local radius too small for the standard manufacturing tool. It may be possible, after deeper examination, to produce a shorter local radius with special tooling.  Please contact your Optimax Sales Engineer for more information.

326

{Side} aspheric surface: slope too high for the standard manufacturing tool. It may be possible, after deeper examination, to produce a shorter normal angle with special tooling.  Please contact your Optimax Sales Engineer for more information.

327

{Side} aspheric surface: sag of surface too large for profilometric measurement.  Please contact your Optimax Sales Engineer for more information.

 

KA-01883

Was this article helpful?
0 out of 0 found this helpful

Comments

0 comments

Article is closed for comments.