Aspheric Polymer Lenses

High-precision aspheric polymer lenses enable superior optical performance by minimizing aberrations that spherical lenses cannot correct. At G&H | GS Optics, we manufacture custom molded aspheric polymer lenses that deliver exceptional clarity, consistency, and cost efficiency - ideal for imaging, illumination, sensing, and AR/VR applications.

Every asphere we produce is optimized for manufacturability and performance through Design-for-Manufacturability (DFM), precision tooling, and rigorous metrology. Our combination of diamond turning, precision injection molding, ensures surface accuracy and repeatability from prototype to volume production.

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.

Applications

• Medical diagnostics & life sciences: imaging, illumination, disposable optics
• Defense & security: night-vision sighting systems, laser collimators
• Industrial automation: machine vision and barcode scanning
• AR/VR & HUD systems: lightweight freeform assemblies
• LED lighting & projection: compact TIR and collimator designs

Manufacturing Capabilities

• Injection molding: 18 systems (20 – 220 tons) for diameters 2.5 – 150 mm
• Surface accuracy: Interferometric verification to λ/10 or better (depending on geometry)
• Cleanroom assembly: ISO Class 7 environment for optomechanical integration
• Thin-film coatings: In-house anti-reflective (AR) and reflective (HR) coatings for visible and NIR bands
• Metrology suite: Zygo Verifire XPZ interferometer, Bruker Contour GT-K1 3D microscope, and Zeiss CMM systems

Advantages of Aspheric Polymer Lenses:

• Aberration correction: Reduces spherical, coma, and astigmatic errors - improving image fidelity and reducing lens count.
• Compact, lightweight design: Polymers weigh two-to-five times less than glass, enabling smaller optical assemblies.
• Manufacturing efficiency: Injection molding replicates complex aspheric surfaces with no cost penalty compared to spherical forms.
• Integration flexibility: Mounting and alignment features can be molded directly into the component, simplifying assembly.
• High-volume scalability: Multi-cavity molds support consistent production from thousands to millions of parts.

Why G&H | GS Optics

• 100+ years of precision polymer manufacturing heritage
• In-house tooling, molding, coating, and assembly
• ISO-certified, DDTC-registered, and U.S.-based production
• Proven DFM and IQ/OQ/PQ process validation
• Engineering partnership from concept through production
• Advanced optical metrology and inspection

Material Selection

We select materials according to optical performance, mechanical robustness, and environmental demands.