Originally posted by sebberry
So here's my question - once the AF and imaging sensor distance differences are compensated for, why would each individual lens have different AF tuning requirements?
Because each and every lens component that affects the distance of the optical block or focusing element from the imaging and PDAF sensors is subject to miniscule but nonetheless significant manufacturing tolerances... tiny,
tiny variances - microns - from specification (it's impossible to manufacture 1,000 of the same component to
exactly the same dimensions so that there's not even one micron of difference). When these components are combined into a fully-assembled lens, the tiny variances in each one can have a cumulative effect.
I've had some recent personal experience of working with manufacturing tolerances - at a much coarser level, admittedly - in the design, prototyping and tweaking of some photographic products I'll shortly be selling commercially. The facilities I'm using to fabricate the components can achieve accuracy of +/- 200 microns, which sounds very small... but when multiple components of different dimensions, with cut-outs, holes for screws etc. come together, the cumulative offset from spec can be +/- 1mm or worse, rendering the product unfit for purpose. It has taken me hundreds of hours to end up with products that, aside from the basic designs, allow for and balance out the tolerances in each component such that every assembled product works as intended. It is a
nightmare... and my products are hilariously simple compared to an autofocus lens

I can't begin to imagine the tolerances they work to...
Originally posted by sebberry
And why is QC so spotty that lenses can focus well at one end, and be OOF at the other? That part completely confuses me - if driving the lens until focused, it shouldn't matter if it's at wide/tele.
I'm less confident on this aspect, but I
suspect it's to do with tolerances in the components that move - or limit the movement of - the optical block and/or focusing element. Again, tiny,
tiny variances that add up when multiple components are combined. QC isn't spotty... it's simply the case that very few of the lenses coming off a production line will be subject to bench-test. If all of them were, the cost of production would sky-rocket, and you could probably double or triple the cost of every lens you buy...
This is nothing new, by the way... these problems existed in the film era too, but few (if any) people noticed them. It's only with the advent of high-resolution sensors and 1:1 pixel-peeping that we photographers can asecrtain small focus inaccuracies...