A numerical double-freeform-optical-surface design method is proposed for beam shaping applications. In this method, both the irradiance distribution and the wavefront of the output beam are taken into account. After numerically obtaining the input-output ray mapping based on Energy conservation using the variable separation method, the two freeform optical surfaces can be constructed simultaneously and point by point corresponding to the ray mapping based on Snell’s law and the constancy of the optical path length. The method is only applicable for separable irradiance distributions. However, such a restriction is fulfilled by many practical laser beam shaping examples. Moreover, the restriction can simplify the computation considerably. Therefore, the method may be quite useful in practice, although it is not applicable to more general cases. As an example, the method was applied to design a two-plano-freeform-lens system for transforming a collimated 20 mm Gaussian laser beam (beam waist: 5mm) into a uniform 10 × 40 mm2 rectangular one without changing the wavefront. Simulation results show that we can obtain a dual lens beam shaping system with the relative root mean square deviation of the irradiance ranging from 0.0652 to 0.326 and the power ratio concentrated on the desired region ranging from 97.5% to 88.3% as the output beam transfers from 0mm to 1000mm.
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