Corrected Recursive Equations for Vane Aperture Sizes and Locations in One- and Two-Stage Stray Light Baffle Systems

Front-end stray light baffles for optical imaging systems are used to limit the amount of out-of-field light that reaches the entrance pupil of the optical system. From star tracker baffles to the outer barrel of the Hubble Space Telescope, it is vital to design the locations and apertures of baffle vanes so that the inner walls of the baffle are not simultaneously visible to both stray light sources and the optical entrance pupil. Various designs have been presented for arbitrary cylindrical baffle tubes and explicitly specified conical tubes, but no working generalized algorithm has been presented where the baffle tube can take an arbitrary conical form. Haghshenas and Johari presented what should be a working recursive algorithm, but the published equations have two errors that result in incorrect output. Corrections to their equations are presented here. Additionally, tolerancing in the field of baffle design has typically been accomplished by slightly increasing the fieldof-view of the baffle system to avoid clipping the optical field due to mechanical tolerance errors. A new way of incorporating fabrication, alignment, and environmental tolerancing is presented that is more consistent with typical mechanical engineering practice and margin against those fabrication errors is included in the recursive equations with demonstration of their benefit.