Precision Optical Prototyping for Demanding Applications

The best optical design software depends on the application, analysis needs, and existing engineering workflow. ZEMAX®, CODE V®, and OSLO® are widely used for optical system modeling and optimization. Apollo Optical Systems has experience with these major optical design programs, alongside mechanical tools such as SOLIDWORKS®, AutoCAD®, Mastercam®, DIFFSYS®, and PTC Creo®, enabling integrated opto-mechanical development.

Optical prototyping is the development of physical optical components or assemblies used to evaluate a design before production. It can include lenses, diffractive surfaces, coated elements, microlens arrays, and multi-element systems. The prototype is fabricated, assembled when required, and measured to verify whether its optical and mechanical performance aligns with the intended design specifications.

Optical prototyping should begin once core performance requirements, operating conditions, and system interfaces are sufficiently defined to create a manufacturable design. Starting early can expose tolerance, material, assembly, or coating constraints before production tooling is committed. A design-for-manufacture review is especially valuable when a concept must ultimately transition from limited prototype quantities to repeatable production.

Yes. Apollo Optical Systems prototypes polymer optical components through single-point diamond turning and injection molding capabilities. Materials may include acrylic, styrene, Zeonex, Zeonor, Ultem, and other specialty polymers selected for optical clarity, birefringence, thermal stability, chemical resistance, or cost requirements. Polymer doublets and triplets can also be fabricated using specialized bonding processes.

Single-point diamond turning can create conic, diffractive, Fresnel, toroidal, aspheric, spherical, and plano optical surfaces. Apollo Optical Systems can diamond turn parts in materials including optical plastics, nickel, brass, copper, and aluminum. This process is particularly useful for producing small quantities of custom components before production molding or for applications requiring complex precision surfaces.

Verification combines design analysis with physical measurement and testing. Apollo performs design verification, tolerance analysis, and in-house metrology to evaluate critical parameters. Available tools include coordinate measurement, optical profiling, microscopy, interferometry, and polarimetry. These methods help assess dimensions, surface roughness, topography, spherical surfaces, and optical retardation where polarization performance is important.

Yes. Anti-reflective, mirror, filter, and beamsplitter thin-film coatings can be applied to prototype optical components made from plastic or glass. Coating selection is based on the required wavelength range and optical function, including UV, visible, or NIR applications. Polymer optics require carefully controlled techniques because their temperature limitations differ from conventional glass components.

Yes. A prototype can be developed with production considerations in mind through an integrated design-for-manufacture review. Apollo evaluates how design requirements, material selection, tolerances, tooling, assembly, and anticipated volume affect feasibility. This approach helps ensure the prototype is not only functional as a test article, but also informs a practical and cost-conscious route to production.