Optical design
Tooling

Optical Tooling

Through a proven network of partner precision toolmakers, the construction of optical mould tools is carried under POL’s tool design and close project management.

In many cases, our specialist toolmakers are skilled in optical surface generation and polishing, so can produce the entire tool set for the product to POL’s specification. However, POL’s extensive partner network of precision machining centres of excellence, enables us to have critical parts of the tool made by different processes and in different geographic locations where necessary, to bring together the best technology mix into the final tooling package. This enables us to design, tool and manufacture novel product applications, selecting the best, most suitable technologies available.

Typically, we use highly inserted tool constructions, which enables the optical surfaces to be more precisely finished and ensures the longevity of the tool by making long term maintenance easier and lower cost. Also, product design changes can be quickly and cheaply accommodated by simple removal and rework or replacement of inserted tool parts. This can make the tool construction more expensive than a cut-in-the-solid tool build, but gives a much more reliable long term performing and design modifications future-proofed solution.

However, we can supply a range of tooling solutions to suit the product development stage, timescale, precision and production expectation of the product, to give the most cost effective and reliable tooling and product supply package.

Tool designs are supported by MoldFlow analyses to verify the expected process performance and optimise the tool construction for reliable product mass manufacture.

Optical ProductsProducts

LED Optics

Polymer Optics “Modular LED Optics”® design, based on a patented hexagonal format, allows maximum packing density and assembly flexibility for a wide range of applications.

We have also developed specialist optics for the latest range of high power UV LEDs emerging onto the market. These are made from high quality optical silicone to give excellent UV transmission with no long term degradation. See POL’s Silicone Optics page for further details.

We design and supply a comprehensive range of high quality, standard products for use with most world-leading LED devices

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Hybrid Reflectors

Hybrid Reflector design uses a central lens to collect and collimate the on-axis light from the LED.

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Lightguides

Our expertise in efficient light control in Lightguide assemblies, enables a lower number of LEDs to achieve the maximum performance.

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Free Form Optics

Free-Form optics are a relatively recent development which offer a step change in the way wide areas are illuminated by LEDs.

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Infrared Optics

Our "engineering with light" approach allows us to provide product solutions for all applications across the whole spectrum from Visible to Infrared.

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Imaging Optics

Developed tooling techniques enable us to produce precision optical surfaces with optical apertures of less than 1mm in diameter, required for miniature camera lens applications.

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Displays

Our design approach, using light scattering pattern techniques, have enabled us to provide high efficiency display illuminations with very compact space envelopes, which use the minimum of light sources and electrical power consumption.

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Eye Protection

Our experience in designing and developing ophthalmic products, enables us to provide precision, impact resistant, eye protection optics for applications such as: fire protection, motor cycle visors, industrial PPE and military systems.

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Street Lighting

Polymer Optics have designed and manufactured a range of optics for street lighting, to meet both the ME and S class regimes of EN13201-2 in Europe and the requirements of IESNA RP-8-00 in the USA.

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Emergency Lighting

Emergency Lighting and Visual Alarm Devices are applications where light from an LED has to be efficiently distributed over a wide area. POL’s free form optics technology is particularly suited for applications which require wide area illumination.

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Silicone Optics

POL can now provide advanced optical product design and rapid manufacture in the latest silicone resins to gain design and cost advantages in our customers’ applications.

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Colour Mixing Technology

Our patented prismatic colour mixing optic was introduced to enable good colour mixing, for narrow beam angle systems, using three discrete LED sources.

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GloWorm®

Brand named “GloWorm®”, the novel lightguide technology enables the light projected from a simple lightguide to be redirected and shaped

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  • LED Optics
  • Hybrid Reflectors
  • Lightguides
  • Free Form Optics
  • Infrared Optics
  • Imaging Optics
  • Displays
  • Eye Protection
  • Street Lighting
  • Emergency Lighting
  • Silicone Optics
  • Colour Mixing Technology
  • GloWorm®