Optical design

Imaging Optics

Plastic optics have many advantages within imaging systems over conventional all glass optic designs. Using plastic optics allows us to;

  • Incorporate aspheric & cylindrical surfaces that reduce the number of optical components required
  • Include mounting and alignment features that reduce the number of mechanical components
  • Integrate reflector surfaces in to housings to improve robustness
  • Mould in plastic including filter dyes, (both visible and near infra-red) that reduce glare and noise
  • Use lower density materials for reduced weight
Polymer Optics has worked with technology leaders to develop innovative imaging solutions.Dyson

One example of this is the Dyson 360 Eye™ robot vacuum cleaner that has a central panoramic camera which is used for navigation.

The requirement was a very demanding one because this was an unconventional lens that needed excellent imaging performance and low manufacturing cost.

To meet Dyson’s specification we used our experience of designing plastic optics to reduce the number of optical parts by making use of aspheric surfaces and multi-optic surface components.


We used our experience in manufacturing optics to optimise the design to find the best imaging performance with the biggest manufacturing tolerances in the areas we know to be most difficult to meet.

POL’s mechanical design experience for optics lead us to make extensive use of self-aligning features that reduced assembly costs and variability ensuring that demanding quality targets could be achieved.

See www.Dyson360eye.com for more details.

If you have a requirement for imaging optics Polymer Optics can help you.

Not all our customers have a full specification for the optical performance of their system and we are often approached by non-optical engineers who need help framing their requirement in optical terms.

POL engineers can help with all stages of a project from an initial review of the options available through to final design and full production if required.


Optical ServicesServices

Design and Development

The latest computer optical design and ray trace programs with optomechanical innovation are used to take full advantage of plastics materials. Complex optical surfaces combined with integral low cost assembly features.



SLA (Stereolithography), SLS (Selective Laser Sintering), Clear SLA, SLA to Vacuum Casting, Direct Machining and Tooling options.



Proven optical quality toolmakers are chosen and assisted by mould flow analysis to optimize the tool. Our specialist toolmakers are skilled in optical surface generation and polishing.


Global Manufacturing

Our moulders are trained in the art of optical moulding. Mould flow process analysis and thorough F.M.E.A. is controlled by the Project Manager to ensure quality and quantity.


Technical Development

Our integrated approach to design enables optical components to become part of the total solution, including how they interface with the other non-optical components.


Optical Coatings and Films

Plastics optical components can be coated in poly-siloxane and acrylate based resin blends to impart more robust properties.


Project Management

Every project has a dedicated Manager to ensure as tasks are actioned, the client is kept informed on progress at each stage. Timing plans are used to monitor progress against agreed milestones and they ensure full control through-out the design, tooling, sampling and production stages.


  • Design and Development
  • Prototyping
  • Tooling
  • Global Manufacturing
  • Technical Development
  • Optical Coatings and Films
  • Project Management