We present two techniques to improve as-built miniature lenses that are defined with high-order aspheric surfaces without losing optical quality and without significantly modifying the layout of the lens. We note that miniature lenses are often defined with more aspheric coefficients than needed. This redundancy can lead to poor as-built lenses. The first technique consists of gradually reducing the number of high-order aspheric coefficients while reoptimizing the lens and maintaining the performance. The second technique consists of desensitizing the lens through a multi-configuration process where different configurations are defined and optimized at the same time. These are the nominal configuration and several perturbed configurations that include lens decenter and tilt. Both techniques are shown to work for improving as-built lenses as we show in two examples from the lens literature.
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