Custom Optical Molds for Specific Optical Designs | Size-Versatile Solutions for the Optical Industry

Core Specifications at a Glance

Core Advantages: Customization, Precision & Size Versatility

1. Tailored to Specific Optical Designs: Precision in Every Feature

• Intricate Feature Replication: Replicate micro-optical details—from 2μm anti-reflective (AR) textures and 5μm prism ridges to free-form lens curvatures and diffuser dot matrices—with 99.95% fidelity. This ensures light behaves as designed (e.g., uniform diffusion in display backlights, sharp focusing in camera lenses, or precise beam shaping in medical lasers).
• Distortion Minimization: Advanced optical simulation (ray tracing + mold flow analysis) optimizes cavity geometry to reduce material shrinkage and residual stress, keeping optical distortion below 0.5%—critical for applications like endoscope lenses or machine vision optics where clarity is non-negotiable.
• Design Collaboration: Our optical engineers work with your team to refine designs for moldability—adjusting draft angles, wall thickness, or feature placement to preserve optical performance while ensuring manufacturability, reducing development time by 30%.

2. Size Versatility: From Micro-Optics to Large-Format Components

• Micro-Optics: Molds for tiny components (φ0.5–10mm) such as fiber optic connectors, micro-LED lenses, and sensor optics, with precision to handle sub-micron features (e.g., 1μm light-guiding grooves).
• Medium-Format: Solutions for consumer optics (20–200mm), including smartphone camera lenses, VR headset optics, and display light guides, with multi-cavity options (4–16 cavities) to boost production efficiency.
• Large-Format: Molds for industrial and automotive optics (200–1000mm), such as automotive headlight lenses, solar concentrator panels, and medical imaging system light guides, with custom cooling to prevent warpage in large, thin-walled structures.

3. Optical-Grade Construction: Materials & Finishes for Clarity

• High-Purity Steel: Uses S136 (corrosion-resistant for cleanroom production), NAK80 (pre-hardened for high-volume), or H13 (heat-resistant for high-temperature resins like COC/COP). These steels are polished to Ra ≤0.003μm—a mirror finish that eliminates surface defects, ensuring molded parts transmit light without scatter.
• Release Optimization: Specialized, optically neutral coatings prevent adhesion between mold and resin (PMMA, PC, COC), avoiding "haze" or micro-scratches that degrade light transmittance.
• Thermal Stability: Precision-machined cooling channels (designed via CFD simulation) ensure uniform resin cooling, preventing internal stresses that cause birefringence in critical optics (e.g., laser collimators or surgical microscope lenses).

Application Scenarios by Optical Industry Segment

Customization & Technical Expertise

• Design Validation: In-house optical labs perform 3D ray tracing and prototype testing to verify light performance (intensity, uniformity, distortion) before full mold production, ensuring alignment with your design goals.
• Rapid Prototyping: Size-specific prototype molds in 12–18 days, using optical-grade resins to validate fit, clarity, and light behavior—accelerating time-to-market for new optical designs.
• Material Matching: Optimize mold parameters for your optical resin (e.g., PMMA for clarity, PC for impact resistance, COP for low birefringence) to maximize performance and yield.

Quality & Service Commitment

• Optical Inspection: Each mold undergoes 3D optical profiling (resolution 0.001μm), interferometry (for flatness), and trial runs with optical testing (spectrophotometry, haze measurement) to verify precision.
• Certifications: Compliant with ISO 9001, with full traceability for materials, design files, and optical performance data.
• Lifecycle Support: Dedicated optical engineers provide maintenance guidelines to preserve mirror finishes and precision, ensuring consistent optical performance over 1,500,000+ cycles.