Applications

• Imaging and projection systems – fold mirrors, relay optics, and off-axis parabolic reflectors
• Defense and aerospace – lightweight mirror assemblies for targeting and sighting systems
• Medical devices – illumination reflectors and diagnostic instruments
• Industrial sensors and scanners – compact reflective components for confined systems
• AR/VR and optical display modules – precision molded mirrors for compact form factors

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:

• Custom mirror diameters from 3 mm to 150 mm
• Flat, spherical, parabolic, and off-axis geometries
• Diamond-turned or replicated surfaces with nanometric finish
• In-house reflective and protective coatings (Aluminum, Gold, Silver)
• ISO Class 7 cleanroom assembly for optical integration
• Advanced optical metrology and inspection

Material Selection for Refractive Optics

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

• PMMA (Acrylic): Excellent clarity and polishability, ideal for high-quality visible mirrors and often used for Imaging and illumination
• Polystyrene: Cost-effective, smooth surface finish, ideal for prototype and high-volume optics and often used for commercial illumination
• Polycarbonate: Impact resistance, broad temperature range, durable for rugged environments and often used for aerospace and field optics
• COP (Zeonex®, Zeonor ®): Low birefringence, low moisture absorption, stable for NIR applications and often used for defense and sensing

Reflective Coatings:

• Aluminum (Al): Broad-band visible reflectivity, durable with protective overcoat
• Gold (Au): High reflectivity in NIR and IR ranges, corrosion-resistant
• Silver (Ag): Superior visible reflectance, used with protective dielectric overcoat

All coatings are applied using our in-house vacuum thin-film deposition systems to ensure uniform adhesion and surface consistency.

Quality Assurance and Process Validation

Reflective 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.

Why G&H | GS Optics

• 100+ years of polymer optics manufacturing in Rochester, NY
• End-to-end control: tooling, molding, coating, and assembly
• ISO-certified, ITAR and DDTC-registered manufacturing facility
• Proven experience in both refractive and reflective optical systems
• Collaborative engineering support from prototype through production
• Advanced optical metrology and inspection facilities