• Current Optics and Photonics
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• v.4 no.6
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• pp.516-523
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• 2020

The normal low-cost manufacturing process for freeform vehicle side mirrors causes deviations from the design curvature. Here, an improved manufacturing process is proposed, combining photorealistic ray-traced visualization of each deviation and subsequent analysis of its deviated reflective scene compared to that of the original design. The proposed mechanism successfully highlights the overlap and mismatch regions of deviated reflected scenes with reference to the desired reflective scenes. We benchmarked the robustness of freeform mirror manufacturing by evaluating the 10, 20, and 30% root-mean-square (RMS) deviated curvature, and concluded that the acceptable deviation needs to be below RMS20% to avoid mismatched regions that could mislead the driver.