The FOSDIGUM consortium, funded by the German Federal Ministry of Education and Research under grant 03INT701CE, carried out a four‑year project (01 May 2020 – 31 December 2023) aimed at establishing a fully digitised production environment for complex optical systems. The core scientific objective was to enable the manufacturing of very short, fully aspherical endoscopic objectives that meet the stringent requirements of modern high‑resolution optoelectronic image sensors. To this end, the project introduced the Forbes G.W. Q‑Type aspherical description, a novel representation of aspherical surfaces based on orthogonal polynomials. This mathematical framework allowed the seamless transfer of simulation, manufacturing, and measurement data across the entire digital process chain, thereby reducing tolerances and improving overall optical performance.

Using the Q‑Type model, the team designed and simulated new lens geometries that incorporated non‑standard curvature profiles, a first for lens manufacturing in this application domain. The chief‑ray angle of the objectives was optimised to match the acceptance cone of contemporary high‑resolution sensors, a parameter that conventional optical fabrication methods cannot adjust. The resulting objectives demonstrated improved image quality and compatibility with the sensor’s field of view, enabling the use of smaller, more compact endoscopes without sacrificing resolution. In parallel, the consortium explored artificial‑intelligence‑based image enhancement techniques. Algorithms developed by Hiottu and VTT were evaluated for super‑resolution, denoising, and illumination correction, providing a pathway to further improve the diagnostic value of endoscopic imagery.

The project’s technical workflow was organised into eleven work packages. Work package 1 focused on project and risk management, establishing a data‑exchange platform and coordinating international collaboration. Work package 2 defined the application scenario and optical specifications, a responsibility shouldered by Karl Storz SE & Co. KG, the world leader in rigid endoscopy. Karl Storz also coordinated the process chain and validated the final modules. FOSDIGUM, as part of the Photonics Hub network, contributed to the internationalisation strategy and facilitated the dissemination of results. Fraunhofer IPT in Aachen served as the consortium coordinator, ensuring alignment across all partners. The AI‑driven image‑processing work was carried out in work packages 9 and 11, where Karl Storz evaluated the algorithms against the end‑user requirements.

Throughout the project, the consortium achieved its primary goals: a unified data‑exchange format was implemented, the Q‑Type aspherical description was integrated into all stages of the production chain, and new lens geometries were fabricated and tested. The AI‑based image‑processing pipeline was demonstrated to enhance image resolution and reduce noise, confirming the feasibility of integrating digital post‑processing with advanced optical design. The project’s outcomes provide a robust foundation for future development of miniature, high‑performance endoscopic systems and illustrate the benefits of a fully digitised manufacturing environment for complex optical assemblies.