Polymer Mirrors

Precision polymer mirrors for high-performance optical systems combine lightweight design with high optical precision, providing a reliable and scalable alternative to glass or metal mirrors.

At G&H | GS Optics, we manufacture custom reflective polymer mirrors that deliver exceptional surface accuracy, reflectivity, and durability for use in imaging, illumination, laser, and defense applications. From flat mirrors to spherical and freeform geometries, our optics are manufactured to meet demanding system requirements while minimizing weight, cost, and assembly complexity.

Applications

• Imaging and projection systems – fold mirrors, relay optics, and light engines
• Medical and analytical instruments – compact reflectors for illumination modules
• Defense and aerospace – rugged, lightweight mirrors for sighting and targeting systems
• Laser and photonics systems – reflective beam steering and collimation
• AR/VR and optical displays – thin, molded mirrors integrated into compact assemblies

Core Capabilities

• Mirror diameters from 3 mm to 150 mm
• Flat, concave, convex, or freeform geometries
• Single- or double-sided reflective coatings
• Coatings in Aluminum, Gold, or Silver with dielectric overcoats for durability
• ISO Class 7 cleanroom for optical assembly and handling

Advantages of Polymer Mirrors

• Lightweight efficiency: 2–5× lighter than glass or metal substrates, ideal for airborne and handheld systems.
• High reflectivity: In-house thin-film coatings achieve >95% reflectance in visible and NIR wavelengths.
• Design flexibility: Complex shapes and mounting features can be integrated directly into the molded part.
• Cost-effective scalability: Injection molding enables rapid replication with tight process control.
• Rugged performance: Resistant to shock, vibration, and temperature variation when properly mounted.

Why G&H | GS Optics

• Over a century of polymer optics expertise in Rochester, NY
• Full in-house control of molding, coating, and metrology
• ISO-certified and DDTC-registered manufacturing facility
• Proven supplier to defense, medical, and industrial markets
• Dedicated engineering partnership to optimize optical manufacturability

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 & Coating Options

Coating Types:

• Aluminum (Al): High reflectivity in visible spectrum, durable with protective dielectric overcoat.
• Gold (Au): Excellent IR and NIR reflectivity, corrosion-resistant for harsh environments.
• Silver (Ag): Superior visible reflectivity with optional overcoat protection for longevity.