Freeform Polymer Optics
G&H | GS Optics manufactures precision freeform polymer optics for imaging, illumination, and AR/VR systems - complex surfaces, lightweight design, and scalable production.
Hybrid & Speciality Polymer Optics
Hybrid and specialty polymer optics for next-generation optical systems combine multiple optical principles - refractive, reflective, diffractive, and waveguide behavior - within a single compact component. At G&H | GS Optics, we engineer and manufacture custom hybrid and specialty polymer optics that enable compact, lightweight, and high-performance solutions for imaging, sensing, AR/VR, and medical instrumentation. From freeform polymer lenses to beam splitters and optical waveguides, our expertise in injection molding, diamond turning, and thin-film coating allows us to produce precision components with complex geometries and integrated features.
Advantages of Hybrid & Specialty Polymer Optics
- Functional integration: Combines multiple optical effects (focusing, splitting, reflection) into one element.
- Compact design: Reduces the number of components in optical assemblies.
- Enhanced optical performance: Maintains high transmission, low scatter, and minimal distortion.
- Scalable manufacturing: Injection molding ensures repeatability from prototypes to high volume.
- Material versatility: Compatible with advanced coatings and hybrid assemblies.
Applications
- AR/VR and wearable displays – integrated freeform and waveguide optics
- Medical devices – hybrid polymer components with reflective and refractive surfaces
- Laser and photonics systems – beam splitting and steering assemblies
- Imaging and illumination modules – compact, multifunctional polymer optics
- Optical sensors and metrology tools – integrated beam routing and polarization control
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:
- Freeform surface generation and replication via diamond turning
- Hybrid diffractive-refractive and reflective designs
- Polarizing and beam-splitting coatings applied in-house
- Integration of optical and mechanical datums in a single molded part
- Molding of polymer waveguides for light routing and coupling
- ISO Class 7 cleanroom for coating, assembly, and testing
- 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): Excellent surface finish and clarity, ideal for visible-range hybrid optics and often used for imaging and illumination
- Polystyrene: High impact resistance, cost-effective for disposable or consumer devices and often used for commercial illumination
- Polycarbonate: Impact resistant, durable for ruggedized hybrid systems and often used for defense and industrial systems
- COP (Zeonex®, Zeonor ®): Low birefringence, thermal stability, precise optical performance in compact systems and often used for AR/VR, sensors
Why G&H | GS Optics
- Decades of experience in multi-functional polymer optics
- Full in-house design, molding, coating, and assembly in Rochester, NY
- ISO-certified, ITAR and DDTC-registered facility
- Proven ability to execute complex, multi-surface optical geometries
- Close collaboration with OEM engineering teams to reduce design risk
| Standard | Precision | |
|---|---|---|
| Focal length (%) | ±5 | ±2 |
| Radius of curvature (%) | ±3 - 5 | ±2 - 3 |
| Power (fringes) | 10 | 5 |
| Irregularity (fringes / 10mm) | 4 | 2 |
| Scratch / dig | 80 / 50 | 60 / 40 |
| Center thickness (mm) | ±0.1 | ±0.05 |
| Flange diameter (mm) | ±0.1 | ±0.05 |
| Concentricity (mm) | 0.1 | 0.05 |
| Center to edge thickness ratio | 1:1 | 3:1 |
| Surface roughness (Å RMS) | <75 | <60 |
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