Molded Infrared (IR) optics are precision optical components manufactured using a controlled molding process, where infrared-transparent materials—most commonly chalcogenide glass—are heated and pressed into high-accuracy molds to form the final optical geometry.
Compared with traditional fabrication methods such as grinding, polishing, and diamond turning, molded IR optics enable high-volume, repeatable, and cost-efficient production, while still achieving the optical performance required for modern thermal imaging and infrared sensing systems.
This technology is particularly well suited for compact lenses, complex aspheres, and multi-surface designs, making molded IR optics a key enabler for next-generation infrared systems.
Key Advantages of Molded Infrared Optics
- Cost-Effective Mass Production: Significantly reduces unit cost for medium- to high-volume production compared to conventional machining and polishing.
- Complex Shapes & Aspheres: Enables fabrication of complex optical geometries that are difficult or impractical with traditional methods.
- High Precision & Repeatability: Advanced molding and quality control ensure consistent optical performance across large production runs.
- Material Versatility: Compatible with IR chalcogenide glass materials optimized for MWIR and LWIR transmission.
- Compact Optical Design: High refractive index materials allow fewer elements and smaller optical systems.
- Rapid Prototyping & Customization: Ideal for fast design iterations during R&D and product development.
Applications of Molded Infrared Optics
- Infrared Imaging Systems: Used in thermal cameras, night vision devices, and compact IR imaging modules.
- IR Communication Systems: Applied in infrared signal transmission and optical coupling components.
- Security & Surveillance: Enables cost-effective production of lenses for security monitoring and perimeter detection systems.
- Infrared Temperature Measurement: Used in non-contact temperature sensing and industrial thermal monitoring devices.
- Consumer & Industrial IR Devices: Suitable for high-volume infrared sensors and compact optical assemblies.
General Specifications – Molded Infrared Optics (Chalcogenide Glass)
Material: IR Chalcogenide Glass
Manufacturing Method: Precision glass molding
| Parameter | Ø 1.0–7 mm | Ø 8.0–20 mm | Ø 20–40 mm | Ø 40–60 mm |
|---|---|---|---|---|
| Surface Roughness | 0.2 μm | 0.3 μm | 0.5 μm | < 1 μm |
| RMS | < 20 μm | < 50 μm | < 100 μm | < 100 μm |
| Eccentricity | ≤ 3 μm | ≤ 5 μm | ≤ 5 μm | ≤ 8 μm |
| Center Thickness Tolerance | ±0.005 mm | ±0.01 mm | ±0.015 mm | ±0.02 mm |
| OD Tolerance | ±0.01 mm | ±0.015 mm | ±0.02 mm | ±0.03 mm |
| Appearance Rating | 40/20 | 40/20 | 60/40 | ≤100/60 |
| Flatness | < 15′ | < 30′ | < 45′ | < 60′ |
Why Choose Molded IR Optics?
Molded infrared optics offer an optimal balance between performance, scalability, and cost, making them ideal for applications where:
- High production volumes are required
- Compact and lightweight optical systems are needed
- Consistent quality and repeatability are critical
- Time-to-market must be minimized
They are increasingly adopted in thermal imaging, automotive IR sensing, consumer electronics, and industrial monitoring systems.
Shapeoptics Molded IR Optics Capabilities
Shape Optics Technologies supplies high-quality molded infrared optics, working closely with advanced manufacturing partners and utilizing state-of-the-art molding equipment and precision process control.
With over 20 years of experience in infrared optics, Shapeoptics helps customers achieve cost-effective, reliable, and scalable IR optical solutions.