Freeform Polymer Optics

Precision freeform optics for complex light management are non-rotationally symmetric optical surfaces engineered to control light in ways that traditional spherical or aspherical lenses cannot. At G&H | GS Optics, we specialize in freeform polymer optics - highly complex molded components that enable advanced light control, compact packaging, and multi-functional optical performance. Our expertise in diamond turning, injection molding, and thin-film coating allows us to replicate intricate freeform geometries with exceptional accuracy, producing components that meet the exacting demands of AR/VR, medical, defense, and photonics applications.

Applications

• AR/VR and head-up displays – integrated optics with asymmetric beam shaping
• Medical imaging – compact freeform elements for diagnostic devices
• Defense and aerospace – lightweight precision optics for rugged environments
• Illumination systems – non-uniform light shaping for automotive and projection
• Machine vision and sensors – compact imaging paths with minimized distortion

Core Capabilities

• Custom freeform optical surfaces up to 150 mm
• Single-point diamond-turned tooling with nanometric surface precision
• Multi-axis injection molding for complex geometries
• Hybrid freeform + diffractive or refractive designs
• In-house AR and HR coating application
• ISO Class 7 cleanroom assembly and inspection

Advantages of Freeform Polymer Optics

• Design freedom: Enables precise light distribution and aberration correction in compact assemblies.
• Integration efficiency: Combines multiple optical functions into a single molded element.
• Lightweight performance: Polymers reduce weight without compromising accuracy or stability.
• Compact system design: Allows shorter optical paths and thinner form factors.
• Scalable production: Injection molding ensures consistent replication across high volumes.

Why G&H | GS Optics

• Decades of polymer optics innovation in Rochester, NY
• Proven expertise in freeform and hybrid optical manufacturing
• End-to-end control: tooling, molding, coating, and metrology
• ISO-certified and DDTC-registered facility
• Collaborative engineering support for design-to-production optimization

Engineering Expertise

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.

Prototypes are diamond-turned using Precitech Nanoform 200 and Nanoform X systems, achieving nanometric surface finish without post-polishing. The same tooling precision transfers directly into injection molds for scalable production.

Quality Assurance and Process Validation

All polymer optics produced by G&H | GS Optics are subject to rigorous quality standards to ensure consistent, reliable performance. Each lens is measured using a variety of metrology equipment to verify dimensional accuracy, surface quality, and refractive characteristics.

To reduce risk after transferring from development to production, GS Optics can conduct a process validation through a combination of installation (IQ), operational (OQ), and performance (PQ) qualifications, ensuring process repeatability and consistent optical performance.

Material & Selection