High Precision Electroforming Molds For Optical Industry

Engineered exclusively for the optical industry, our custom optical molds are tailored to replicate specific optical designs with uncompromising precision—offering full size versatility to meet diverse application needs, from micro-optics to large-format components. Leveraging decades of optical engineering expertise, we transform complex optical designs (lenses, prisms, light guides, and diffusers) into high-performance molds that ensure consistent light transmission, minimal distortion, and flawless replication, making them indispensable for industries ranging from consumer optics to medical imaging and industrial photonics.

Our molds are engineered to bring your unique optical designs to life with exacting accuracy:

• Intricate Feature Replication: Replicate micro-optical details—from 2μm anti-reflective (AR) textures and 5μm prism ridges to free-form lens curvatures and diffuser dot matrices—with 99.95% fidelity. This ensures light behaves as designed (e.g., uniform diffusion in display backlights, sharp focusing in camera lenses, or precise beam shaping in medical lasers).
• Distortion Minimization: Advanced optical simulation (ray tracing + mold flow analysis) optimizes cavity geometry to reduce material shrinkage and residual stress, keeping optical distortion below 0.5%—critical for applications like endoscope lenses or machine vision optics where clarity is non-negotiable.
• Design Collaboration: Our optical engineers work with your team to refine designs for moldability—adjusting draft angles, wall thickness, or feature placement to preserve optical performance while ensuring manufacturability, reducing development time by 30%.

We support full size flexibility to match the optical industry's diverse needs:

• Micro-Optics: Molds for tiny components (φ0.5-10mm) such as fiber optic connectors, micro-LED lenses, and sensor optics, with precision to handle sub-micron features (e.g., 1μm light-guiding grooves).
• Medium-Format: Solutions for consumer optics (20-200mm), including smartphone camera lenses, VR headset optics, and display light guides, with multi-cavity options (4-16 cavities) to boost production efficiency.
• Large-Format: Molds for industrial and automotive optics (200-1000mm), such as automotive headlight lenses, solar concentrator panels, and medical imaging system light guides, with custom cooling to prevent warpage in large, thin-walled structures.

Mold materials and finishes are selected to maximize optical performance:

• High-Purity Steel: Uses S136 (corrosion-resistant for cleanroom production), NAK80 (pre-hardened for high-volume), or H13 (heat-resistant for high-temperature resins like COC/COP). These steels are polished to Ra ≤0.003μm—a mirror finish that eliminates surface defects, ensuring molded parts transmit light without scatter.
• Release Optimization: Specialized, optically neutral coatings prevent adhesion between mold and resin (PMMA, PC, COC), avoiding "haze" or micro-scratches that degrade light transmittance.
• Thermal Stability: Precision-machined cooling channels (designed via CFD simulation) ensure uniform resin cooling, preventing internal stresses that cause birefringence in critical optics (e.g., laser collimators or surgical microscope lenses).

• Design Validation: In-house optical labs perform 3D ray tracing and prototype testing to verify light performance (intensity, uniformity, distortion) before full mold production, ensuring alignment with your design goals.
• Rapid Prototyping: Size-specific prototype molds in 12-18 days, using optical-grade resins to validate fit, clarity, and light behavior—accelerating time-to-market for new optical designs.
• Material Matching: Optimize mold parameters for your optical resin (e.g., PMMA for clarity, PC for impact resistance, COP for low birefringence) to maximize performance and yield.

• Optical Inspection: Each mold undergoes 3D optical profiling (resolution 0.001μm), interferometry (for flatness), and trial runs with optical testing (spectrophotometry, haze measurement) to verify precision.
• Certifications: Compliant with ISO 9001, with full traceability for materials, design files, and optical performance data.
• Lifecycle Support: Dedicated optical engineers provide maintenance guidelines to preserve mirror finishes and precision, ensuring consistent optical performance over 1,500,000+ cycles.

For the optical industry's most demanding designs, our custom optical molds deliver the precision, size versatility, and optical performance needed to turn visionary optical concepts into reliable, high-quality components—regardless of size or complexity.