Optical design

Infrared Optics


Polymer Optics Limited is a leading suppliers of Passive Infra-Red (PIR) lenses and PIR lens design services to the security and lighting control industries. While our lenses are mostly used for security and lighting applications they have numerous other area sensing applications for products such as fan control, door activation, temperature measurement and general energy management.Polymer Optics’ designers have been at the forefront of PIR lens design for over twenty years. Our in-house developed ray-trace software can accurately predict the performance of the PIR lens before committing to tooling. We also develop novel manufacturing methods for precision tooling manufacture and high quality moulded lenses. New rapid manufacturing techniques allow fully working prototype lenses to be made within ten working days of design completion and a much faster route to final production tooling.Polymer Optics’ patented Free-form Fresnel (FF) technology ensures the lens detection zones are undistorted and highly focused for higher resolution and more reliable zone sensing.These ground-breaking techniques improve our design and manufacture and ensure we remain at the forefront of the PIR industry.

3D PIR lens for lighting control. The lens has 16 detection zones and 180deg field of view.

Raytrace simulation showing PIR detection zones projected onto walls and ceiling. This type of simulation tool helps visualise the performance of the lens and confirms the product design performance.

Raytrace simulation showing predicted signal response across PIR detection zones. These simulations are used to ensure that an acceptable signal is available from all the Fresnel facets, to guide the product’s electronic design.

Conventional Fresnel lens gives distorted zone image.

Pol Fresnel lens gives undistorted zone image.
POL’s new Free-form Fresnel (FF) lens technology helps to reduce distortion and improve lens focal properties.

Case Study

Using POL’s Free-form Fresnel (FF) lens technology, it is now possible to make high performance flat lens arrays, which previously could only be achieved in 3D formed lens products. POL has used this new technology in a 31 detection zone PIR lens array called the FF31 and is available as a standard product. Part number 452

Previously it was only possible to maintain zone definition by tilting the Fresnel facets, meaning that the lens had to have a 3D appearance.

Using POL’s new lens facet design, it is now possible to create a more aesthetically pleasing flat lens, which can be flush fitted into low profile wall and ceiling mounted detectors.

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