Optics for Single-Use and Disposable Endoscopes

A borescope is generally used to inspect hard-to-reach spaces in industrial equipment, engines, pipes, or structures. An endoscope is designed for medical visualization inside the body and must meet much stricter requirements for patient safety, imaging performance, materials, and device integration. Both may use small lenses, illumination, and imaging systems, but their intended environments and regulatory considerations differ substantially.

The cost of a single-use endoscope varies widely based on device type, imaging technology, diameter, articulation, illumination, sterile packaging, and production volume. Optical costs are affected by lens count, polymer choice, coatings, tolerances, assembly method, and inspection requirements. Early design-for-manufacture work can help teams identify cost drivers and establish a scalable optical architecture before committing to production tooling.

Polymer optics can offer a cost-effective route to producing precise lens components at volume, particularly when a design is optimized for injection molding. Materials such as Zeonor and Zeonex provide strong optical clarity, low birefringence, and useful chemical resistance. The appropriate material depends on wavelength needs, sterilization exposure, dimensional stability, environmental conditions, and the required imaging performance of the finished device.

Yes. Apollo combines optical and mechanical design, design verification, tolerance analysis, diamond-turned prototype optics, polymer injection molding, coating, assembly, and metrology capabilities. This integrated approach helps teams evaluate performance and manufacturability as a program progresses. Production methods can be selected for the expected volume, from manual prototype setup and semi-automatic fixturing to automation-oriented assembly strategies.

Anti-reflective coatings are commonly used to reduce unwanted surface reflections and improve transmission within a defined wavelength range. Depending on the optical architecture, mirror, filter, or beamsplitter coatings may also be relevant. Polymer optics require coating processes that account for material temperature limitations. Coating selection should be based on the imaging sensor, illumination source, spectral requirements, lens material, and device environment.

Optical and mechanical tolerances influence focus, field of view, distortion, contrast, illumination uniformity, and overall image consistency. In a compact endoscope, small variations in lens geometry, spacing, alignment, or material properties can compound across the system. Tolerance analysis uses manufacturing realities to predict performance variation, enabling engineers to balance demanding image requirements with processes that can be reliably produced at the intended volume.

Testing can include mechanical and optical surface measurement, surface roughness and topography evaluation, interferometry for applicable spherical parts, microscopy, and polarization measurement when required. The relevant inspection plan depends on the component’s geometry, material, optical function, and design specifications. In-house metrology helps verify critical parameters and provides feedback that supports process control, design refinement, and confidence before system-level integration.

Design-for-manufacture review is most valuable early, before the optical architecture, materials, tolerances, and assembly approach are fixed. Early review can identify features that are difficult to mold, coat, align, inspect, or assemble consistently. It also helps evaluate cost and performance tradeoffs before production tooling is committed. Revisiting the review after prototype testing can further refine the route to scalable manufacturing.