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Optical and mechanical tolerances for two-lens plano-aspheric laser beam shapers

This paper presents a systematic discussion of the optical and mechanical tolerances which must be addressed in order for a laser beam shaper system to perform close to the design criteria. First, a general relationship based on the intensity law of geometrical optics is presented, which relates the input and output beam profiles, and particular attention is given to the common Gaussian input beam profile. Next, the impact of collimation errors of the input beam is addressed. Then, lens mounting errors for a two-lens laser beam shaper are addressed including lens spacing, decenter, and tilt tolerances. Overall, this paper addresses actual variations of the deterministic transformation of an input irradiance profile into an output beam profile, whether it employs refractive, reflective or diffractive optical elements.