Various Sizes and Customization for Specific Optical Designs Optical Castings

Crafted for the precision demands of the optical industry, our optical castings combine full size versatility with tailored customization for specific optical designs—delivering high-clarity, dimensionally accurate components that meet the strict performance requirements of diverse optical applications. Whether replicating complex lenses, prisms, light guides, or diffusers, our castings are engineered to preserve optical integrity, minimize distortion, and adapt to sizes ranging from micro-optics to large-format structures, making them ideal for consumer electronics, medical imaging, industrial photonics, and automotive optics.

Our optical castings are engineered to bring your unique optical designs to life with uncompromising accuracy:

• Complex Feature Replication: Replicate intricate optical details—from 3μm anti-reflective textures and 10μm prism facets to free-form lens curvatures and micro-structured diffusers—with 99.9% fidelity. This ensures light behaves as designed, whether for uniform backlighting in displays, sharp focusing in camera lenses, or precise beam shaping in medical lasers.
• Design Alignment: Our engineering team collaborates with your optical designers to optimize casting parameters (e.g., mold flow, cooling rates, and material selection) for your specific design, ensuring the final casting retains critical optical properties like refractive index consistency and minimal aberration.
• Performance Validation: Pre-production simulations (ray tracing, mold flow analysis) verify that castings meet light transmission, diffusion, or guidance targets, reducing trial-and-error and accelerating time-to-market.

We offer full size flexibility to match the breadth of optical industry needs:

• Micro-Optics: Castings for compact components (φ1-10mm) such as fiber optic connectors, micro-LED lenses, and sensor optics, with precision to handle sub-10μm features (e.g., light-guiding grooves or micro-prisms).
• Medium-Format: Solutions for consumer and medical optics (10-200mm), including smartphone camera lenses, VR headset optics, and endoscope light guides, with multi-cavity casting options to boost production efficiency for high-volume needs.
• Large-Format: Castings for industrial and automotive applications (200-1200mm), such as automotive headlight lenses, solar concentrator panels, and industrial illumination light guides, with controlled cooling to prevent warpage in large, thin-walled structures.

Our casting processes and materials are selected to maximize optical performance:

• High-Clarity Materials: Use optical-grade resins (PMMA for superior clarity, PC for impact resistance, COC/COP for low birefringence) and glass-reinforced composites (for thermal stability), ensuring castings transmit light with minimal absorption or haze.
• Precision Casting Techniques: Advanced molding processes (injection casting, compression casting) with vacuum degassing eliminate air bubbles and voids—critical for maintaining light transmittance (≥92% for PMMA/PC) and preventing optical defects.
• Surface Finish Excellence: Post-casting polishing (Ra ≤0.005μm) and anti-reflective coatings enhance light transmission and reduce glare, making castings ideal for high-performance optics like machine vision lenses or surgical microscope components.

• Design Collaboration: Our optical engineers provide DFM (Design for Manufacturability) insights to refine your design for casting, optimizing features like wall thickness, draft angles, and texture placement to preserve optical performance.
• Rapid Prototyping: Size-specific prototypes in 10-15 days, using production-grade materials to validate optical clarity, dimensional accuracy, and light behavior before full-scale production.
• Material Matching: Recommend optimal resins or composites based on your application's needs (e.g., heat resistance for automotive, biocompatibility for medical, or low birefringence for laser optics).

• Optical Inspection: Each casting undergoes 3D optical scanning (resolution 0.01μm), haze/transmittance testing, and birefringence analysis to verify compliance with design specs.
• Certifications: Compliant with ISO 9001, with full traceability for materials, design files, and performance data.
• Lifecycle Support: Provide guidelines for handling, cleaning, and maintenance to preserve optical integrity, ensuring long-term performance in end applications.

For optical components requiring tailored designs, size flexibility, and uncompromising clarity, our optical castings deliver the precision, versatility, and quality needed to elevate your optical systems—from micro-optics to large-format structures.