Advantages of Plastic Optics

A case for using plastic optics

The decision to use glass or plastic really depends on the application, the properties of the materials, and the limitations of the molding process. Properties of thermoplastics that make them attractive for use as optics include:

• They are lighter in weight than glass (about a factor of 2 to 5 lighter)
• They are moldable

How does the manufacturing process drive the decision?

• Injection molding is a highly efficient method of reproducing complex surface geometries
• Using injection molding, one can integrate mounting features and optics into one platform
• Molding can be done in various quantities with a high degree of repeatability
• Molds can be built with more than one cavity, thus economies of scale are achieved

Polymer optics should be considered if:

• The application involves a fairly high number of components
• The optic has a combination of optical and mechanical features that are integrated onto one platform
• If the optical surface is aspheric or is otherwise complex, even low quantities may be more cost effective to produce by injection molding because of the use of multi-cavity molds

Polymer optics can be coated

• Physical vapor deposition coatings routinely done
• AR coatings such as broad band visible or v-type coatings
• Reflective coatings such as protected or enhanced Gold, Silver, and Aluminum
• Generally applied at lower temperatures than glass type substrates so coatings are not as robust