Optical Design & Engineering Services
Many optical projects fail during mass production due to gaps between design assumptions and manufacturing realities.
ATRMOLD provides end-to-end optical design and engineering services, focusing on manufacturable optical design, mold feasibility, and long-term production stability.
Our engineers bring 10–20 years of experience in optical lens design and injection-molded optics, bridging design and manufacturing.
Discuss Your Optical Project
Manufacturable Optical Design for Stable Mass Production
Our optical design process integrates mold structure, injection parameters, and material behavior from the earliest stages.
- Optical lens and imaging system design
- Ray tracing, optical simulation, and tolerance analysis
- Material selection for PMMA, PC, and optical-grade plastics
- Design optimization linked to mold construction and process limits
- Long-term repeatability and yield-focused engineering
Engineering-Led Customer Services
We support customers from feasibility evaluation to stable mass production, integrating optical design, precision mold development, and injection molding into one framework.
Customer Service Workflow
- Requirement review and feasibility assessment
- Optical design and simulation with tolerance control
- DFM review and mold feasibility validation
- Precision mold development
- Trial molding and process validation
- Mass production ramp-up and yield optimization
Production-Oriented Optical Design Capabilities
- Optical system design using Zemax / OpticStudio and Code V
- Multi-material optical design (PMMA, PC, optical glass)
- Critical angular error control ≤ 0.001°
Engineering Case – Medical Optical Lens
A U.S. medical device customer faced instability due to a 0.2 mm diameter deviation. ATR re-evaluated optical geometry, tolerance allocation, and mold feasibility, restoring stable performance.
The redesigned lens has remained in mass production for over five years.
Precision Processing Equipment
- 5-axis FANUC machining centers (±0.0005 mm repeatability)
- Precision machining of aspheric and freeform optical surfaces
- Zeiss mirror EDM with surface finish Ra ≤ 0.02 μm
- Machining strategies optimized for molding behavior and stress control
Closed-Loop Testing & Verification Systems
Testing is integrated into both design validation and production control to ensure batch-to-batch consistency.
- Zygo Interferometer (λ/10) for surface and wavefront accuracy
- Zeiss CMM with ±0.0003 mm measurement accuracy
- Shimadzu UV-Vis spectrophotometer for transmission validation
Industry-Specific Optical Solutions
- VR & LED Optics: High-transmission PMMA and mirror-polished molds
- Protective Eyewear: Dimensional tolerance control within ±0.02 mm
- Aspheric & Freeform Lenses: Complex geometries with low distortion
- Medical Optics: Dynamic temperature control achieving >98% yield
Quality Assurance & Proven Manufacturing Capabilities
- ISO 10110 compliant optical design verification
- Mold inspection using Zeiss CMM and Zygo interferometry
- Production monitoring with thermal cycling (-40°C to 85°C)
- Full traceability with shipment approval
