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Visible vs. Infrared Optics: What Changes in Lens Design and Manufacturing (SWIR & LWIR) Infrared optics bring a different set of constraints compared to visible imaging. The wavelength band, material selection, thermal behavior, and coating requirements often redefine both design choices and manufacturing control points. Below is a practical overview for SWIR and LWIR projects. 1) Materials and transmission Visible optics commonly use optical glass families, while IR optics often require specialized materials to achieve transmission in SWIR or LWIR. Material choice influences weight, cost, manufacturability, and achievable surface performance. 2) Coatings are band-specific Coatings must be specified for the operating band and angle. An AR coating optimized for visible wavelengths will not deliver the same effect in IR. For IR projects, always define band, AOI, and (if relevant) polarization and environment. 3) Thermal behavior matters (athermal considerations) Temperature changes can shift focus and image performance. Many IR systems require thermal stability considerations, which affects mechanical interfaces, assembly tolerance strategy, and validation during ramp-up. Clear operating temperature assumptions help prevent integration surprises. 4) Tolerances and assembly strategy In imaging lenses, not every tolerance carries equal optical impact. A practical approach prioritizes the features that most affect performance and relaxes non-critical items to improve yield and cost. Sharing the system context (sensor size, FOV, integration constraints) enables better DFM decisions. 5) Validation from sample to production For IR lenses, it is common to validate not only geometry but also real imaging performance under intended conditions. A pilot build is often the most efficient step to confirm stability before scaling to volume. What to send for an IR lens inquiry Band (SWIR or LWIR), wavelength range, and application scenario Sensor format, target FOV, and key performance priorities Mechanical interface constraints and operating temperature assumptions Target quantities and timeline (prototype / pilot / volume) Planning an IR project? Share your band, system constraints, and timeline. We can support DFM review, prototyping, and production coordination with a practical, scalable route.

How to Specify Optical Coatings Without Surprises (AR, HR, Beam Splitters & Filters) Many coating issues are not caused by “bad coating” but by incomplete specifications. Performance changes dramatically with wavelength range, angle of incidence (AOI), polarization, substrate material, and environmental conditions. This article provides a practical specification checklist to help your coating behave as expected in real use. Why coating performance changes Wavelength range: targets at 532 nm can differ from 400–700 nm broadband requirements AOI (angle): a coating designed at 0° may shift at 30° or 45° Polarization: S and P polarization can behave differently at higher AOI Substrate: material index and absorption affect achievable performance Environment: humidity/temperature cycles can influence durability requirements A coating specification checklist To avoid rework, include the following items in your inquiry or drawing notes: Optical function: AR / HR / beam splitter / filter type (bandpass, longpass, shortpass, ND, etc.) Wavelength range and targets: define passband/stopband or reflectance targets and bandwidth AOI: operating angle(s), not just “normal incidence” Polarization: unpolarized or specify S/P requirements Substrate: material and thickness (or allow supplier recommendation) Surface and cosmetic expectations: application-driven (imaging vs. industrial sensing differs) Durability: cleaning method, handling, and any environmental constraints Examples that reduce ambiguity Broadband AR: specify the wavelength range and max reflectance target at the operating AOI Beam splitter: specify split ratio, AOI, and polarization conditions Bandpass filter: specify center wavelength, FWHM, blocking range, and OD target (if needed) ND filter: specify optical density (OD) or transmission, and wavelength range What we recommend for faster projects If you are unsure about coating trade-offs, start with your application scenario and operating conditions. A short technical discussion upfront usually saves multiple sampling cycles later. Need a coating recommendation? Share your wavelength range, AOI, polarization, substrate preference (if any), and target performance. We can propose a practical specification and sampling plan.

From Prototype to Volume: A Practical Guide to Optical Component Manufacturing Moving an optical component from prototype to stable volume production is rarely a single-step process. The best outcomes come from clear specifications, early manufacturability discussion, and a controlled ramp-up plan. Below is a practical roadmap used in many successful projects—especially when consistency matters as much as “one good sample”. 1) Start with the right input A drawing is necessary, but not always sufficient. For faster engineering review and fewer iterations, include: Optical material, wavelength range, and key performance targets Surface quality expectations (application-driven) Coating type (if needed), angle of incidence, and polarization conditions Tolerance priorities (what must be tight vs. what can be relaxed) Target quantities and delivery timeline 2) Engineering review (DFM) saves time later DFM (Design for Manufacturability) is where cost and yield are often decided. A good review identifies risk areas early—before sampling—such as overly strict tolerances on non-critical features, coating requirements that conflict with angle/polarization, or surface specs that exceed the real application need. 3) Prototyping: validate function, not only appearance Prototype samples should validate optical function and integration fit. If the component is part of an assembly (e.g., lens + spacer + housing), consider sharing the interface constraints so sampling can target the real system requirement. 4) Pilot build: lock the route before mass production Pilot build (small-batch trial) is where process stability is confirmed. Typical goals include: confirming yield, verifying inspection criteria, and aligning acceptance standards. This is the step that turns “one-time success” into repeatable delivery. 5) Volume production: consistency and traceability In volume supply, customers care about repeatability. Define how consistency is checked, what records are kept, and what traceability level is required (project-based). This reduces ambiguity when issues occur and shortens corrective-action cycles. Common pitfalls (and how to avoid them) Undefined priorities: specify what matters most (performance, cost, lead time, cosmetic) Coating ambiguity: include wavelength + AOI + polarization + target performance Over-tight tolerances: tighten only the features that impact function No ramp plan: prototype ≠ mass production—pilot builds bridge the gap Need support? Send drawings/specs (or samples), target quantities, and timeline. We can provide DFM feedback and a practical manufacturing route for sampling, pilot build, and volume production.