복합 폴리머 광학: Jenoptik의 정교한 사출 성형 공정을 사용한 부품 및 시스템

 

By utilizing 2-component injection molding, we merge two separate steps into one seamless process, increasing efficiency and reducing production time. This innovative approach for polymer optical solutions allows us to combine two different materials and/or colors into a single operation, resulting in a more streamlined and cost-effective manufacturing process - even for high volumes and medical components.

• Enabling less assembly steps
• No complex and costy assembly of components
• Shrinkage compensation
• High performance optical properties & surface accuracy
• Two different materials and/or colors

Injection molding and stamping procedures are used to produce polymer optics with aspherical surfaces at the same cost as spherical optics.

Our aspherical polymer lenses have a non-spherical surface to improve the quality of optical images. Using a diamond processing method, we produce high-precision aspherical lenses and tool inserts very efficiently. We use these in turn to mold aspherical polymer lenses. Depending on the size and shape, these lenses can achieve a global dimensional accuracy of PV < 1µm and micro roughness of Ra < 10 nm.

With the injection molding and stamping procedure, aspherical polymer surfaces can be molded just as precisely as spherical surfaces — for the same cost. Therefore, aspherical contours are therefore widely used in polymer optics.

• Diameters from < 1 mm to 300 mm UPT-optical inserts
• PV depending on size and shape up to <1 μm
• Surface roughness optical inserts <10 nm
• Multi-cavity

 A lens is an optically effective component with two refractive surfaces. At least one surface of the lens is not a plane face. This increases the quality of images. Jenoptik offers lenses in a wide range of shapes for your specific polymer based applications: From the prototype to large-scale production, we can produce

• Aspherical lenses
• Cylinder lenses
• Lens arrays
• Lenses with free-form optics
• Toric lenses

We offer expertise along the entire technology chain — from component design, tool construction, injection molding and optical coatings through to fully automatic production. Our production is technologically adapted to your specific batch size and is designed to deliver a very high degree of dimensional accuracy.

 

Polymer prismatic surfaces can be used to deflect light beams and achieve spectral splitting. Polymer optics offer the advantage of enabling you to integrate prismatic surfaces together with other optical functional surfaces and mechanical functional elements in one component. For example, you can use spherical and aspherical lenses, cylinder lenses or micro structures together with prisms. The components are produced in just one work step using sophisticated injection molding and stamping processes, saving you both time and cost.

Jenoptik produces prismatic surfaces of 0.01 - 100 mm for your specific applications.

• Prism sizes range from tiny components to greater assemblies
• Customized shapes & designs
• High angle accuracy
• CCM measurements for quality assurance

 

Polymer fresnel lenses are divided into a set of concentric annular sections. The individual sections are then merged on a plane. These lenses are ideal for optical applications in the fields of lighting, medical, science, machine vision, photography and photovoltaics, for example.

Thanks to ultra-precise processing technologies such as diamond tools and lathes, we can realize fresnel structures with very small groove distances as small as 0.05 mm. On our special lathes, we produce precise spherical and aspherical fresnel lenses as individual items or in small batches. Convex, concave or even bi-focal structures can be produced, adapted perfectly to your specific requirements.

• Customized designs possible due to inhouse tool and UPT shop
• Individual designs with sharp inner and outer edges & high form accuracy

Free-form optics are not rotationally symmetrical and can be used, amongst other things, for the collimation of light, beam formation, imaging and complex light diffusion. The optics have asymmetric characteristics. To ensure accurate processing of these polymer optical solutions with ultra-precise lathes, special experise is required along the entire process chain. At Jenoptik we take care of free-form optics projects from the design stage through to system integration.

With our Slow Tool Servo technology, we can produce high-precision free-form optics with diameters ranging from 1 to 350 mm. We use a modified diamond turning procedure, which uses a controlled rotation axis as well as two linear axes. The part of the free-form optics that is not rotationally symmetrical is achieved by means of a dynamic movement of the tool toward the optical axis.

The process is ideal for diamond processing of polymers (PMMA, Zeonex, PC, PS) and metals (nickel-phosphor, aluminum, copper, brass). Depending on your particular application, we can produce the free-form optics in a wide range of shapes.

• Sophisticated tooling expertise of complex freeform optics
• High precision molding & CCM quality control 
• Functional injection molding

 

Thin, deposited metal layers can be used as the front or back mirror surface for reflectors. You can combine aluminum, silver or gold with other protective coatings to adapt them to your specific requirements. Aluminum is ideal for broadband reflectors in the VIS range and well into the IR range. The additional protective coatings mean you can use aluminum as a mirror coating even under challenging environmental conditions, such as in condensing humidity. On the other hand, you can increase the coating's reflectivity by combining it with a dielectric coating.

Silver mirrors offer excellent VIS reflection properties and are used in moderate environmental conditions. Gold mirrors have a proven track record in the infrared spectral range in particular. The reflection properties in this range are excellent and offer long-term stability.

If metallic solutions are not suitable for your optical application, we can also offer dielectric mirrors on polymers for certain wavelength ranges. Therefore, we have developed procedures for a range of transparent and non-transparent polymers. We can also apply mirror coatings to substrates with complex three-dimensional shapes.

Experience unparalleled accuracy with our fully automatic sensor adjustment, boasting a remarkable precision of up to +/- 1 μm. Our cutting-edge competencies and facilities are designed to cater to a wide range of applications, ensuring seamless integration and optimal performance in various industries of our polymer optical solutions.

• Industry-Leading Accuracy
• Unmatched precision: +/- 1 μm accuracy for precise measurements and data acquisition
• Automated calibration: Effortless adjustment and calibration for enhanced reliability and reduced downtime
• Versatile applications: Suitable for various industries

 

Our ultra-precise assembly competency for polymer optical solutions and opto-electronics, sensor assembly and packaging is poised to revolutionize a wide range of applications, from consumer electronics to medical devices and aerospace technologies. By harnessing the power of precision assembly, we are empowering innovators and manufacturers to create polymer optical systems that are more efficient, more compact, and more powerful than ever before.

• Ultra fast UPT prototyping of polymer optics with tight tolerances
• Dicing up to 12 inch and several materials
• Die-Bonding in the area of thenths of milimeter
• Wire-Bonding up to 75 µm
• Housing and encapasulation
• Testing