Many injection molders have underestimated the complexity of this blended technology and have been quick to announce their participation in the optic marketplace leading to many costly failures over the years. Even some well-established, high value added injection molders have struggled to enter this market. Unlike most technologies that usually transition into a commodity over time, precision optics has remained a unique niche for several decades.

In addition, there is a wide range of applications for plastic optics within the marketplace that require different levels of expertise. Collimating a beam of light for example requires less precision than imaging applications.

So how can a buyer identify the right plastic optic supplier for a given application? It's very realistic to expect that a correct choice can be made in selecting a qualified precision, plastic optic supplier by following the guideline provided below.

A site visit is the best way to access a supplier's true capability. The best candidates are often restricted by non-disclosure agreements which make it difficult to provide parts for evaluation or details portraying their capability. Plastic optics is still a unique niche that can not be evaluated without due consideration. If a visit is not feasible, extensive research and communications are essential for making the right decision.
A precision optical molder should have experienced optic engineers and/or technicians on staff. Don't lose sight of the fact that you are dealing with accuracies within a specified number of wavelengths that requires optical analysis, troubleshooting and verification on site daily.

A qualified supplier should be expected to pursue a clear understanding of the optical requirements of your specific application; otherwise, how can you be confident that they can deliver the desired results?

Solely relying on external technical support is a mistake. Optical expertise is required throughout the whole product cycle including quote, tool design & build, processing, daily production support, and product qualification. It is not reasonable to expect continuous improvement or cost reductions from a supplier that does not have this necessary optical support internally nor should you be confident that they can deliver to your specifications.

In addition, continuous corporate down-sizing have dramatically reduced the technical experience that may once have resided internally. One thing that appears to have been ignored in this process is the amount of engineering support that larger companies were once providing to their suppliers. In most cases this support is a thing of the past, meaning that, your supplier of choice must now be capable of resolving technical problems on their own.

Optical metrology and quality control:

Obviously it is impossible to be an optic manufacturer without the ability to measure optical specifications. There is some very basic metrology that should be found on site.

Interferometer - a device that separates a beam of light into two ray beams, usually by means of reflection, and that brings the rays together to produce interference, used to measure wavelength (or accuracy of the optical surface)

Spectrophotometer - an instrument used to determine the intensity of various wavelengths in a spectrum of light; transmittance and reflectance (verification of optical coatings). If the spectrophotometer does not have the proper fixturing for measuring reflectance, then a Reflectometer should be available.

Profilometer - is a measuring instrument used to measure a surface's profile or quantify its roughness. Key instrument for single point diamond turning.

Measuring Microscope with digital imaging and vision processing metrology - a device that utilizes high power magnification for accurate, direct measurement of part features. Another key device in support of single point diamond turning.

In addition, proper optic regulations are critical and the shortest path to project success. Look for evidence that personnel are trained and certified appropriately for optic inspection, handling, and tool care.

Demonstrated skill of this blended technology

Any experienced precision injection molder will acknowledge that tooling and process development become more difficult with parts that have complex geometric shapes. When optical surfaces are added, the complexity and difficulty increases significantly. This is the primary reason that some plastic lens molders chose to only focus on simple lenses.

However, one of the key advantages of plastic lenses is the ability to mold additional features around that lens that eliminates or reduces the need for auxiliary mounts, alignment and hardware. The very best optical molders have developed the capability to maintain accurate optical surfaces while adding these cost reducing features and boldly encourage their customers to take full advantage of plastic benefits

Internal capabilities:

Many companies present themselves as having a full range of optic capability while in fact they utilize external supplier to fill, what I would describe as, their internal gaps. The right choice should have essential capabilities under one roof.

Single Point Diamond Turning - an ultra precision CNC diamond turning lathe that produces superior optical surface finishes and consistent accuracy in plastic and metals. Though there are other methods for fabricating optical inserts in support of lens molding, SPDT is a crucial capability to have on location. This equipment also enables prototyping and low volume production capacityTantiopticsofficial.com

Thin Film Optical Coating - vacuum deposited thin films, on the order of wavelengths, used to create optical coatings. Layers at this scale accurately effects the way an optic reflects or transmits light. Optical coating is required for many applications and is best when it is located and managed close to the molding operation.

Tool design and build - a fully equipped tool room utilizing the latest technologies supported by CNC software and skilled craftsmen to build molds in-house, ensures that new molds will be built with dollar-saving speed and accuracy, or tool transfers will be properly evaluated with problems proactively resolved.