Why are very large-aperture superzoom lenses so difficult to make?

Asked 1/24/2018

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What physical and optical limits make an extreme lens such as a hypothetical 5–600mm f/2 impractical? I’m less interested in market demand and more in the lens-design side: aperture, focal length, glass size, light behavior, manufacturing complexity, tolerances, and overall size/weight. In general, what limits do lens makers hit first when trying to build a zoom lens with both a huge focal-length range and a very large maximum aperture?

Originally by Photography Stack Exchange contributor. Source · Licensed CC BY-SA 4.0

Photography Stack Exchange contributor

8y ago

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For a simple lens design - since I'm decently new to optics and can't do the math any other way...

A 600mm f/2 lens would need...

f/number = (focal length)/(entrance pupil)

--> 2 = 600/x

--> x = 300mm

So, the front element would need to be at least 300mm in diameter.

Canon released specially made 1200mm f/5.6 lenses which would have, theoretically, had ~214mm front elements.

These lenses were prohibitively expensive and few were made...(I think they released at $90,000 - but are now well north of 6 figures.)

So, even if you pulled one of those elements into your 600mm lens, you'd still only have a ~f/2.8 lens.

So, the reality of the physics of optics has already squashed the idea of a 600mm f/2 - at least as far as creating one that would be marketable (and not just a great science project).

Now, you want to add a zoom to this equation?

Originally by user67377. Source · Licensed CC BY-SA 4.0

user67377

8y ago

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The biggest hard limit is optics: the f-number is focal length divided by entrance-pupil diameter. So at 600mm, an f/2 lens needs an entrance pupil about 300mm wide. That implies an enormous front element, huge glass, high weight, and very difficult manufacturing tolerances.

A zoom makes this much harder. A 5–600mm lens would need to work over an extreme focal-length range while keeping that large aperture, which means many large elements moving precisely relative to each other. As zoom range increases, correcting aberrations across the whole range becomes much more complex.

Large apertures also make optical flaws more obvious, so the lens design must control aberrations very tightly. Bigger elements are harder to shape, polish, coat, align, and support. The result is a lens that would be extremely large, heavy, and expensive.

So the first limits are mainly physical optics and engineering: required entrance-pupil size, aberration correction over a huge zoom range, and the practical difficulty of making and aligning very large glass elements. Economics matters too, but even before that, the lens quickly becomes impractically big and complex.

UniqueBot

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8y ago

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