Grinding and polishing have,for many decades, been the tried-and-true way to shape and finish optical lenses and surfaces. Today, however, optical lens manufacturers are turning to automated processes like injection molding and precision glass molding. Because they offer high optical accuracy and efficiency, these newer techniques help reduce overall production costs.
It’s important to understand which method best suits your project when you’re working on plastic or glass lens designs. Below, we’re breaking down injection molding and precision glass molding to help you choose the right method for your application.
Injection molding for plastic optics
Precision injection molding is a well-known method for producing complex plastic optics at scale. Its high repeatability and excellent surface quality, as well as flexibility in design, are all important in fast and varied modern optical applications.
Why use injection molding for optical components?
Design flexibility
Injection molding makes it possible for optical lens manufacturers to replicate intricate geometries, including aspheric lenses and diffractive structures. This capability supports compact and highly integrated optical designs.
Cost-effective for high volumes
The process is economical for high-volume production while maintaining consistent optical quality. Compared to grinding and polishing glass, cycle times are much shorter, helping reduce overall production costs.
Lightweight and durable
Plastic optics are much lighter and more impact-resistant than glass, making them ideal for mobile devices and wearable technology.
Built-in functionality
Injection molding can accommodate advanced polymers that can deliver lenses with UV filters and anti-reflective properties in a single lens design.
Using precision glass molding
Precision glass molding works similarly to plastic injection molding, but one major difference is cycle time — while a plastic lens can be produced in under 30 seconds, glass molding typically takes 15 to 30 minutes per cycle.
In addition, glass molding uses higher temperatures that could shorten the lifespan of tools, raising the overall costs of manufacturing. Regardless of these challenges, some optical lens manufacturers may still recommend glass molding for applications that require superior optical performance.
About the company
At Light Works, LLC, we specialise in designing and building high-precision specialty optics for the machine vision industry. Our expertise includes hypercentric (pericentric) and telecentric lenses, optical view splitters, and comprehensive optomechanical engineering services. We focus on delivering tailored solutions for complex imaging applications, ensuring distortion-free, accurate, and reliable performance. With a strong commitment to innovation, precision, and quality, we provide optical solutions that meet the most demanding industrial and research requirements.
