Providing a means for engineers to create high-performance optics at volume quantities, a novel replication process transfers the profile of a precision optical surface from a master, creating an exact duplicate on a variety of substrates. The process can produce a wide range of both ruled and holographic diffraction gratings, reflective and transmission holographic optical elements, and dual wavelength gratings, as well plano and conic sections. Diffraction gratings are produced in sizes up to 110mm x 110mm with groove densities from 40 g/mm to 3600 g/mm, with available wavelengths from the deep UV to the far IR. Substrate materials include glass, silicon carbide, ceramic, and metals such as beryllium, aluminum, titanium, stainless steel, and others. Additional mounting holes and other features such as tabs can be incorporated into the metal replica. Surface accuracy and radii are certified to customer specifications using a ZYGO™ interferometric measuring system, profilometer, or other measuring system depending on the optic configuration.
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