Precision Optical Assemblies Built to Perform

Optical components are individual parts that transmit, reflect, focus, filter, split, or otherwise control light. Common examples include lenses, mirrors, filters, prisms, windows, diffusers, microlens arrays, and beamsplitters. In an optical assembly, these components are selected, positioned, bonded, or mechanically mounted so they work together to meet imaging, illumination, sensing, laser, or display performance requirements.

A lens typically includes one or more optical surfaces, a clear aperture that passes usable light, an edge or rim, and defined geometry such as spherical, aspheric, Fresnel, or diffractive features. In a finished assembly, a lens may also have an optical coating, mechanical mount, spacer, adhesive bond, or retaining feature. Multi-element lenses add multiple aligned components to control aberrations and achieve targeted performance.

Apollo assembles UV-bonded doublets and triplets, air-spaced doublets and triplets, multi-element assemblies, glass/polymer hybrid systems, refractive/diffractive hybrids, opto-medical devices, and opto-electronic devices. Programs can range from one-of-a-kind assemblies to hundreds of thousands per month. Available methods include mechanical assembly, manual prototype setup, semi-automatic fixturing, automation, UV bonding, and ultrasonic welding.

Yes. Apollo supports early prototypes through high-volume assembly programs. Single-point diamond turning can produce custom optical prototypes before production molding, while assembly methods can be matched to volume requirements. Manual setup supports prototype work, semi-automatic fixturing supports lower volumes, and automation can be used for higher-volume production. Design-for-manufacturing review helps evaluate whether a design can scale practically.

Apollo works with polymer and glass optical components, plus selected metals for machined optical surfaces and mechanical elements. Its polymer expertise includes acrylic, styrene, Zeonex, Zeonor, Ultem, polycarbonate, and other specialty materials. Material selection considers optical clarity, refractive index, birefringence, heat resistance, moisture or chemical resistance, sterilization needs, dimensional stability, and cost targets.

Apollo uses in-house metrology to measure critical optical and mechanical parameters. Available equipment includes coordinate measurement systems, optical profilometry, high-magnification microscopy, scanning white-light interferometry, digital compact interferometry, larger-part interferometry, and polarimetry. These tools support measurement of surface roughness, topography, spherical and aspheric surfaces, mechanical dimensions, and retardation on polarization-critical components before production decisions are finalized.

Apollo provides thin-film optical coatings for plastic and glass components, including anti-reflective, filter, mirror, and beamsplitter coatings. Coating solutions can address UV, visible, and NIR requirements and are available from prototypes through high-volume batches. Polymer optics require careful temperature-aware coating techniques, so material behavior and application requirements are evaluated as part of the coating approach.

Tolerance analysis evaluates how normal variation in component dimensions, surface quality, positioning, and mechanical interfaces can affect system performance. It helps optical and mechanical engineering teams balance performance goals with realistic manufacturing capability. By identifying sensitive dimensions and alignment requirements before production, tolerance analysis can reduce rework risk, inform inspection priorities, and support assemblies that perform consistently across manufactured units.