Custom Prototyping for Precision Optical Systems

Prototype cost is driven by the optical design complexity, material, size, surface geometry, quantity, coating requirements, tolerances, assembly needs, and validation scope. A diamond-turned single component has different requirements than a coated, multi-element assembly. Apollo reviews the intended application and production goals to define an efficient prototype approach and a quote aligned with the required level of performance.

Apollo can support precision optical components and assemblies for imaging, illumination, laser, LED, diffractive, and micro-optics applications. Prototype surfaces may include spherical, aspheric, Fresnel, conic, toroidal, plano, and diffractive geometries. Available materials include several optical polymers and metals, while coating, bonding, and multi-element assembly can be incorporated when the design requires them.

Involve a prototype manufacturer as early as possible, ideally while optical and mechanical requirements are still being defined. Early input can identify material, tolerance, coating, assembly, and fabrication considerations that affect performance and cost. This enables design-for-manufacturing decisions before a design becomes difficult or expensive to change, while keeping future production needs visible from the start.

Yes. Apollo provides independent design verification for pre-existing optical designs. The process can include simulation, optimization, tolerance analysis, and prototype testing to identify aberrations or performance issues. Verification compares the design and physical prototype against the intended specifications, helping teams understand whether the concept is ready for fabrication, refinement, or production planning.

Timing depends on design maturity, component geometry, material availability, fabrication method, coating requirements, assembly complexity, and testing needs. A well-defined single component generally follows a different schedule than an integrated optical assembly requiring multiple fabrication and validation stages. Reviewing requirements early helps Apollo sequence design, manufacturing, and measurement work efficiently and establish a realistic project timeline.

Yes. Apollo’s design-for-manufacturing review considers whether prototype performance can translate into a practical production solution. The team evaluates tolerances, material selection, part geometry, molding suitability, coating constraints, assembly methods, and anticipated volume. This reduces the risk of developing a prototype that works technically but cannot be made consistently or cost-effectively at the required scale.

Apollo uses in-house metrology equipment to measure critical mechanical and optical parameters. Capabilities include coordinate measurement, optical profiling, microscopy, interferometry, surface roughness and topography measurement, and polarization-related measurement. The appropriate testing plan is based on the prototype’s specifications, allowing the team to confirm key characteristics and compare actual performance with the intended design requirements.

Yes. Prototype programs can include thin-film optical coatings and assembly support when required for functional evaluation. Apollo offers anti-reflective, filter, mirror, and beamsplitter coating options for plastic and glass components. Assembly capabilities include bonded doublets and triplets, air-spaced and multi-element systems, hybrid glass-polymer designs, and manually set up prototypes before higher-volume methods are considered.