Precision Glass & Injection Molded Plastic Optics

At Lensel, we pride ourselves on the diverse knowledge base of our engineering team, the diverse skill sets of our workforce as well as the diverse range of manufacturing facilities at our disposal. This allows us to assist customers at every stage of the Product Realization Process from initial design, to prototyping to final bulk scale supply. Along with primary design, we are also experienced with reverse engineering any glass or plastic optical system. By measuring all the optical parameters as well as analyzing the glasses, we have been able to accurately reproduce complex optical systems. We are careful to ensure that no patent infringement occurs during the reverse engineering process.
Over the last few years, we have assisted our foreign and domestic customers in creating a wide array of diverse and interesting products. Some of these have been described briefly below. In light of Non-Disclosure Agreements signed with all our customers, we are only at liberty to divulge very basic, non-specific information on these products.

With a fully equipped glass shop, an extensive test plate collection in excess of 500 testplates and 24 skilled workers, the Lensel glass optics manufacturing facility is well suited for high quality, small and medium sized production runs varying from very high quality single unit requirements (such as large λ/10 windows) to medium sized lots of 500 to 5000 lenses.

We routinely supply glass optical lenses to the following specifications:

Material	Optical Glasses of all types (Schott, Pilkington & China), float glass, pyrex, Fused Silica, Quartz, ZnSe, BaF2 etc
Diameter	4 mm to 250 mm.
Optical Surface	Spherical, aspheric, parabolic
Precision		Commercial	High Precision
	Diameter	± 0.10 mm	± 0.05 mm
	Thickness	± 0.10 mm	± 0.04 mm
	Centering	± 3 arc min	± 1 arc min
	Focal Length	± 2 %	± 0.5 %
	Scratch / Dig	60 / 40	20 / 10
	Surface Figure	5 fringe / 1 Irr	λ/10

At Lensel Optics, we have a fully equipped, dust-proof Injection Molding Facility with 3 PrecisionInjection Molding machines and a wide variety of molds. We manufacture plastic optics for a wide range of applications such as magnifiers, low vision devices, prisms, receiver-emitters, condensers, imaging systems, aspheric lenses etc. We also design & fabricate custom made OEM plastic optical elements to suit specific applications. Our fully equipped Tool Room allows us to make the molds ourselves thereby providing our customers with very economical Mold making costs. Main advantages of plastic optics lie in low per piece cost; integral molding of mounting fixtures (making assembly simpler & more economical); easy & highly economical production of aspheric surfaces and other complex forms; light weight and break-resistance.

We routinely supply plastic optical lenses to the following specifications:

Material:	Acrylic (PMMA), Polycarbonate, Polystyrene, and Zeonex.
Diameter:	4 mm to 130 mm.
Optical Surface:	Spherical, aspheric, others (faceted, fluted, non-symmetrical)
Shape:	Optical surface along with integrally molded mounting frame, fixture, spacer etc.
Precision:	Diameter tolerance : ± 0.10 mm; Thickness tolerance : ± 0.10 mm; Centering tolerance: 3 arc min; Scratch/Dig : 60/40; Focal length tolerance : ± 1%;

Lensel Optics began production in 1979 with the making of large compression molded fresnel lenses for Overhead Projector Application. We continue to manufacture the highest quality Fresnel lenses using the compression technique. Today, these lenses have a variety of applications including Overhead Projectors, Large Area Magnifiers and Solar Collectors.

We have a large collection of Fresnel Molds as well as standing stocks of Fresnel lenses of sizes and focal lengths given below:

Size	Thickness	Focal Length
285 mm x 285 mm	2mm	340mm
285 mm x 285 mm	2mm	330mm
310mm x 310mm	2mm	340mm
310mm x 310mm	2mm	220mm
640mm x 480mm	4mm	600mm

Apart from the above Fresnel Lenses, we are also willing to get customized molds made for customers requiring large quantities of lenses

Our primary coating chamber is a 24 inch diameter vacuum chamber suitable for multi-layer Broadband Anti-reflective coatings. The coating system has a sophisticated digital thickness monitoring system as well as an Electron-Beam Gun to allow for the deposition of multiple layers of various coating materials. We routinely coat Glass, Acrylic (PMMA) and Polycarbonate lenses. Our standard BBAR coating is optimized for minimum reflections in the visible range. (Transmission curve) In addition, we can also provide a special anti-scratch layer that is extremely useful in increasing the scratch resistance of scratch prone materials such as Polycarbonate, PMMA and polystyrene.

Our secondary coating chamber is a 19 inch diameter vacuum chamber suitable for single layer coatings. This coating system is geared for single layer MgF2 Anti-reflection coatings as well as Aluminum deposition Mirror coatings.