Applications

• Laser beam shaping and splitting
• Compact imaging systems – chromatic correction and lightweight design
• AR/VR optics – diffractive waveguides and holographic displays
• Biomedical instruments – spectroscopic and diagnostic systems
• Illumination and projection – Fresnel and hybrid collimation optics

Design for Manufacturability (DFM)

Based on decades of expertise, G&H | GS Optics engineers provide our customers with DFM recommendations to ensure that their polymer optics programs are successful. Using mold flow simulations, we can model how resin will fill the mold during the injection molding process to better position gates, anticipate where knit lines will appear, and locate difficult to fill spots in the mold. G&H | GS Optics specializes in scientific injection molding which is a systematic, data-driven methodology to produce world class polymer optics.

Core capabilities include:

• Micro-structured features down to 250 nm pitch
• Custom diffractive lens diameters up to 150 mm
• Hybrid refractive/diffractive lens designs for chromatic correction
• Precision diamond-turned or etched master tooling
• Replication via optical-grade polymer molding
• In-house AR and reflective coatings for enhanced efficiency
• ISO Class 7 cleanroom assembly and inspection
• Advanced optical metrology and inspection facilities

Material Selection for Diffractive Optics

We use optical-grade thermoplastics engineered for diffractive performance and coating compatibility:

• PMMA (Acrylic): High visible transmission, smooth surface replication, ideal for visible diffractive lenses and often used for imaging and illumination
• Polystyrene: Smooth mold replication, cost-effective, ideal for high-volume diffractive optics and often used for commercial illumination
• Polycarbonate: Impact resistant, dimensionally stable, durable for rugged environments and often used for consumer or disposable systems
• COP (Zeonex®, Zeonor ®): Low birefringence, low moisture absorption, maintains groove fidelity and phase stability and often used for sensing, AR/VR

Quality Assurance and Process Validation

Diffractive polymer optics undergo interferometric and profilometric metrology to verify feature depth, pitch accuracy, and surface form. G&H also performs optical efficiency testing and scatter analysis to ensure that molded microstructures match their theoretical design. All production runs are qualified through IQ/OQ/PQ validation, ensuring consistency across volume manufacturing.

Why G&H | GS Optics

• Over 40 years of experience producing diffractive and hybrid optics
• In-house design, tooling, molding, coating, and metrology in Rochester, NY
• ISO-certified, ITAR and DDTC-registered facility
• Proven track record in defense, medical, and photonics industries
• Collaborative engineering partnership from optical modeling through production