Microlens Arrays

Precision Polymer microlens arrays for imaging and sensing are miniature optical elements that control, focus, or distribute light across very small apertures. At G&H | GS Optics, mold custom polymer microlens arrays that deliver exceptional alignment accuracy, uniformity, and optical efficiency for imaging, sensing, AR/VR, and fiber-optic communication systems.

Applications

• Image sensors – light coupling and focus correction
• Optical communication – fiber coupling, beam shaping, and mode control
• AR/VR & head-up displays – lightweight micro-optics for compact systems
• Biomedical instrumentation – illumination and detection modules
• LIDAR & laser systems – uniform beamlets and structured-light projection

Core Capabilities

• Lenslet diameters from 10 µm – 2 mm
• Spherical, aspheric, and freeform geometries
• Master tooling created via diamond turning with nanometric surface finish
• Multi-cavity molds for scalable production
• In-house AR coatings and Class 10,000 cleanroom assembly
• Interferometric or profilometric inspection for every array zone

Advantages of Polymer Microlens Arrays

• Compact optical integration: Hundreds of elements in one lightweight polymer component.
• Superior uniformity: Consistent focal length and optical power across the full array.
• Design freedom: Molded aspheric or freeform geometries without additional cost.
• Scalability: Precision replication from prototype to millions of parts.
• Cost-effective performance: Injection molding minimizes per-unit cost for high-volume programs.

Why G&H | GS Optics

• Decades of experience in polymer micro-optics and array molding
• Fully integrated manufacture, tooling, coating, and metrology under one roof
• ISO-certified and DDTC-registered U.S. facility
• Proven manufacturing repeatability for micro-structured optics
• Collaborative engineering support from concept through 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.

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

We use optical-grade polymers optimized for clarity, refractive index stability, and environmental performance: