Abstract Profile error of free-form surface is evaluated in this paper based on sequential quadratic programming (SQP) algorithm. The optimal localization model is established with the minimum zone criterion firstly. Subsequently, the surface subdivision method or STL (STeror Lithography) model is used to compute the point-to-surface distance and the approximate linear differential movement model of signed distance is deduced to simplify the updating process of alignment parameters. Finally, the optimization model on profile error evaluation of free-form surface is solved with SQP algorithm. Simulation examples indicate that the results acquired by SQP method are closer to the ideal results than the other algorithms in the problem of solving transformation parameters. In addition, real part experiments show that the maximum distance between the measurement points and their corresponding closest points on the design model is shorter by using SQP-based algorithm. Lastly, the results obtained in the experiment of the workpiece with S form illustrate that the SQP-based profile error evaluation algorithm can dramatically reduce the iterations and keep the precision of result simultaneously. Furthermore, a simulation is conducted to test the robustness of the proposed method. In a word, this study purposes a new algorithm which is of high accuracy and less time-consuming.