US-Based Optics Manufacturing and Domestic Supply

Apollo Optical Systems manufactures precision polymer optical components in Rochester, New York. Its domestic capabilities include single-point diamond turning, polymer injection molding, thin-film coatings, optical assembly, and in-house metrology. Components can include spherical, aspheric, Fresnel, diffractive, and microlens-array features, along with coated and assembled optical systems. Material and process selection is guided by the application’s performance, volume, and environmental requirements.

Apollo manufactures a broad range of precision optical components, including spherical, aspheric, Fresnel, diffractive, toroidal, and plano surfaces. The company works with optical polymers and selected metals through diamond turning and injection molding. It also produces microlens arrays, polymer doublets and triplets, custom diffusers, and hybrid glass-polymer or refractive-diffractive assemblies for applications requiring specialized optical performance.

Yes. Apollo supports custom optical prototypes through single-point diamond turning and design-for-manufacturing collaboration, then can apply injection molding and assembly methods for scalable production. Assembly ranges from one-of-a-kind builds to hundreds of thousands of units per month, depending on the product configuration. Early production planning helps align surface geometry, material choice, tolerances, and tooling needs with volume objectives.

Apollo works with optical-grade materials including acrylic, styrene, Zeonex, Zeonor, Ultem, polycarbonate, specialty polyester resins, and other performance polymers. Each material offers different tradeoffs involving transmission, birefringence, refractive index, heat resistance, chemical resistance, moisture resistance, and cost. Engineering collaboration helps identify a material that supports the product’s optical, environmental, sterilization, and manufacturing requirements.

Apollo provides thin-film optical coatings for plastic and glass components, including anti-reflective, filter, mirror, and beamsplitter coatings. Coatings can be developed for UV, visible, and NIR wavelength ranges. The team has specialized experience with polymer optics, where temperature limitations affect coating choices and process conditions. In-house fixture design supports coating approaches tailored to component geometry and application needs.

Apollo uses in-house metrology equipment to evaluate critical mechanical and optical characteristics. Available tools include coordinate measurement, optical profiling, microscopy, scanning white-light interferometry, compact interferometry, large-part interferometry, and polarimetry. These methods help assess surface roughness, topography, figure, geometry, and optical retardation. Verification is used to confirm that components and prototypes align with applicable design specifications before production decisions are made.

Yes. Apollo provides design-for-manufacturing reviews, design verification, and tolerance analysis to help customers evaluate whether an optical concept can meet performance and budget objectives in production. Optical and mechanical considerations are assessed together, reducing disconnects between modeled designs and physical parts. Reviews can identify practical adjustments to materials, tolerances, fabrication processes, coatings, and assembly approaches before tooling or full-scale manufacturing begins.

Apollo supports optical programs serving defense and aerospace, medical and life sciences, tactical, industrial and commercial systems, lighting, consumer, and automotive markets. Its capabilities are suited to imaging, illumination, laser, LED, telecommunications, machine vision, diagnostics, biometrics, display, and scanning applications. The appropriate process depends on component geometry, wavelength range, volume, durability requirements, and the system’s overall performance targets.