Serial production
of plastic lenses
At ALL-IN OPTICS, we provide various services such as the mass production of plastic lenses.
We have highly trained experts with more than 15 years of experience dealing with such high-quality productions.
Different transparent materials are designed for the specific market and application, and these materials play an important part in our day to day lives.
This production is cost-efficient and of high-quality, but before the series is possible, a whole process connection must be completed from lens design to producing the prototype.
Injection Moulding
The production of transparent material within injection moulding needs to be carried out by special injection moulding machinery. The handling of the product and process of the material needs to be also strictly carried out. There needs to be a high requirement paid to plastic product quality; any hole, marking, whitening or discoloration must be eliminated as it will be visible within a transparent Lens.
During the storage and transportation stage, the material must be sealed and kept clean. If or when drying stages are happening the air used should be filtered to avoid polluting the raw material. The main Materials that are used for producing plastic Lenses are PMMA, PC, COC or COP Material.
Plastic injection moulding is the process of melting plastic granulate that once malleable enough, are injected at pressure into a mould cavity, which fills and solidifies to produce the final product. Related to the Lens production there might be some special processes which are needed some times – such as Compression Moulding or variothermal heating and cooling. The steps of producing high-quality transparent lenses are Grinding, polishing, Anti-glare contacting, and finishing.
Hot embossing
Hot embossing is a technique to fabricate high-quality microstructures. The technique can be quite a challenge due to the high surface volume ratio. The typical materials used for this are PMMA, COP, COC, and PC. There need to be significant steps taken within this process.
There are typically four steps of embossing, pre-heating, embossing, demoulding, and cooling. The requirement is good process control at elevated temperatures and is often used for large area polymer devices with micro and nanostructures such as microlenses and anti-reflective polymer films.
Plastic injection moulding is the process of melting plastic granulate that once malleable enough, are injected at pressure into a mould cavity, which fills and solidifies to produce the final product. Related to the Lens production there might be some special processes which are needed some times – such as Compression Moulding or variothermal heating and cooling.
Serial production of glass lenses
Grinding
Starting off with the Grinding, the technician chooses the appropriate semi-finished Material and covers it in plastic to protect the surface as the other side is ground. Molton metal is used on the cover side for a block or hold. Grinding is performed by a CNC machine using tens of thousands of natural diamond machining points.
Polishing
Polishing is the next step, as the lens will still consist of rough circles. To smooth the lens and maintain the correct shape, we use abrasive sandpaper and water at a temperature of 19 degrees celsius. We then polish the lens again this time using sandpaper with a compound of aluminum oxide, water, and polymers. After the surface smoothing is complete we remove the block and plastic covering the back of the lens and clean the lens with a 15 step chemical bath. Our experts will accurately inspect the lens each step of the way.
