In recent years, there has been a significant increase in interest in free-form micro-optical arrays (FMOAs) owing to their microscopic dimensions and their ability to address certain limitations of rotationally symmetric optical components. Nevertheless, although free-form micro-optics enhance optical device performance and compactness, the intricate and segmented surface shapes introduce numerous challenges during design, fabrication, and quality control. In this article, we examine the innovative advancements made by PHABULOμS in computer-aided design (CAD) tools capable of analyzing FMOA designs and identifying manufacturing constraints, thereby reducing the need for time-consuming and costly adjustments in later stages.

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