🔷 Custom Optical Shapes

Tailored Optics for Unique System Requirements

At Yighen Ultra Precision, we understand that not all optics come in standard forms. Many advanced optical systems—whether for imaging, illumination, or beam manipulation—require custom-shaped optical components to achieve specific functionality or fit within mechanical constraints. From freeform geometries to irregular apertures and hybrid profiles, we offer full-spectrum services for designing and manufacturing custom optical shapes with ultra-high precision.

🔶 What Are Custom Optical Shapes?

Custom-shaped optics refer to any optical element that deviates from traditional geometries like spherical lenses or simple cylinders. These may include:

• Irregular apertures (elliptical, hexagonal, notched edges)

• Freeform surfaces with non-rotational symmetry

• Off-axis segments of aspheres or mirrors

• Prisms with complex entrance/exit angles

• Hybrid surfaces combining refractive and diffractive zones

These components are essential in systems where light needs to be shaped, folded, corrected, or directed in non-standard ways—particularly in compact optics, head-mounted displays, medical probes, laser beam shaping systems, and more.

🛠️ Our Capabilities in Custom Optics

Yighen supports full-cycle development of non-standard optics:

🔧 Design & Simulation

• Advanced surface modeling in Zemax, Code V, Freeform Design Tools

• Optimization for tilt, decenter, thermal and mounting tolerances

• CAD support for mechanical fit & optomechanical integration

💎 Precision Machining

• Diamond turning for plastics, CaF₂, MgF₂, and freeform substrates

• Ultra-precision grinding & polishing for glass, fused silica, and ZnSe

• Edge shaping, notching, holes, bevels with micron-level accuracy

• Surface accuracy: P-V ≤ 0.1 µm, Ra ≤ 2.0 nm

🧩 Materials Supported

• Optical polymers (PMMA, COP, APEL, ZEONEX, OKP-1)

• Glass substrates (BK7, fused silica, SF11, IR-grade materials)

• Specialty coatings compatible with complex geometries

🧪 Typical Custom Shape Applications

📦 Sample Work We Deliver

• Custom prisms with angled chamfers or split-path exits

• Aspheric-Fresnel hybrids for compact illumination optics

• Mount-ready irregular optics with holes, grooves, notches

• Optical substrates with pre-assembled metal frames or bonding pads

✅ Why Choose Yighen?

• In-house manufacturing (not outsourced) in our Dongguan facility

• Precision machining backed by 5-axis diamond turning & ULG grinding

• Rapid prototyping: delivery in 2–3 weeks

• Quality assurance with full inspection reports (interferometry, centering, surface quality)

❓ FAQ – Custom Optical Shapes

Q: Can you manufacture freeform optics with mounting holes or slots?
A: Yes, we routinely add edge holes, cutouts, or mechanical interfaces directly during precision grinding or turning.

Q: What’s your smallest supported aperture or thickness?
A: We can produce optics as small as 1.0 mm in diameter or 0.3 mm thickness depending on material and design.

Q: Do irregular shapes affect coating uniformity?
A: We use advanced fixturing and rotation techniques to ensure coating consistency even for complex geometries.

🧩 Unlock Design Freedom with Tailored Optical Geometries

Yighen specializes in manufacturing unconventional optical shapes — whether it’s off-axis, polygonal, annular, wedge-shaped, or fully custom contours.
We support glass, infrared materials, and high-performance polymers using freeform diamond turning, precision grinding, and CNC shaping — all verified with full-surface metrology.

From prototyping to mass production, we bring your unique optical path to life.

🔵 Request a Custom Shape Feasibility Review
📩 Send us your optical concept or 3D file — we’ll advise on design-for-manufacturability and suggest optimal shaping techniques.

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Need to explore material compatibility or shape complexity?
📄 Download Our Optical Shaping Capabilities Overview

Want to understand how we integrate custom optics into assemblies?
👤 Meet Our Engineering Team

🔗 Related Content

• 🌀 Freeform Optics
  Engineered for non-rotationally symmetric designs and compact layouts.

• 🧪 Reverse Optical Engineering
  We reconstruct and redesign legacy optics into manufacturable CAD files.

• 🛠 Opto-Mechanical Design
  Custom housings and alignment features for non-standard optics.

• 🔍 Optical Metrology & Testing
  Surface profile, clear aperture, and form error validation for complex geometries.