🔷 TIR Lenses (Total Internal Reflection Lenses)

Precision Beam Control through Total Internal Reflection

TIR lenses (Total Internal Reflection lenses) are specially engineered optical components that combine refraction and internal reflection to achieve high-efficiency light collimation, beam shaping, and light concentration—all within a compact, single-piece structure.

At Yighen Ultra Precision, we offer custom TIR lens design, rapid prototyping, and volume production, optimized for LED optics, illumination systems, optical sensors, and more. Whether you need a standard profile or a complex freeform TIR lens, our engineers ensure optimal optical performance, thermal stability, and manufacturability.

🔹 How TIR Lenses Work

A TIR lens typically includes:

• A refractive entry surface to collect divergent light (e.g. from an LED)

• An internally reflective conical or curved surface that reflects light through total internal reflection (TIR)

• An output surface to direct and shape the exiting beam

This structure enables >90% optical efficiency without metallic coatings or mirrors, making TIR lenses ideal for compact, high-output light systems.

🔹 TIR Lens Applications

We tailor lens profiles to meet specific FWHM, divergence angles, and optical path requirements.

🔹 Material Options for TIR Lenses

We machine or mold TIR lenses using the following optical-grade polymers:

• PMMA (Acrylic) – Excellent transparency, widely used for LED optics

• PC (Polycarbonate) – Impact-resistant for outdoor or rugged applications

• COP / COC (APEL, ZEONEX, TOPAS) – Low birefringence and high mold accuracy

• IR-Grade Polymers – Optional for NIR/MIR light concentration

Materials are selected based on thermal performance, optical index, UV stability, and injection moldability.

🔹 Yighen’s Manufacturing Capabilities

Our in-house tooling shop and mold core machining (Ra ≤ 0.001 µm) ensure tight dimensional control and high-fidelity groove structures.

🔹 Prototyping to Production – The Yighen Workflow

1. Custom Optical Simulation – Our optical designers validate beam angles, efficiency, and spatial distribution.

2. Rapid Diamond Turned Prototypes – Machined in PMMA, COP, or ZEONEX for quick evaluation.

3. Injection Mold Tooling – Diamond-turned metal molds prepared at Yighen’s Dongguan facility.

4. Optical Coatings (Optional) – AR, IR, or reflective coatings applied upon request.

5. Volume Production & QA – Every batch inspected for optical clarity, geometry, and beam uniformity.

❓ FAQ

Q: Can I get a prototype TIR lens before mold investment?
A: Yes, we provide diamond-turned TIR lens prototypes within 10–15 working days.

Q: Do you support freeform TIR profiles?
A: Absolutely. We design and machine freeform LED TIR lenses for asymmetric or complex beam profiles.

Q: What’s the typical beam divergence you support?
A: We design for anything from narrow spot beams (5°–10°) to wide-angle diffusers (50°–90°), based on your LED characteristics.

💡 Precision LED Collimation Starts Here

Yighen designs and manufactures high-precision TIR (Total Internal Reflection) lenses tailored for LED lighting, optical sensors, and compact beam-shaping systems.
Our expertise spans both rotational and freeform TIR geometries, supporting high-transmission polymers like PMMA, COP, and PC with ultra-low surface roughness.

We offer complete optical and mechanical integration — from CAD modeling to prototyping and volume production.

🔵 Request a TIR Lens Design Review or Quotation
📩 Share your light source specs, beam angle requirements, and mechanical constraints — we’ll provide optimization suggestions within 24 hours.

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Need to check tolerances or surface specs?
📄 Download Our TIR Lens Manufacturing Guide

Learn how Yighen supports tight-angle collimation and optical uniformity?
👤 About Us

🔗 Related Content

• 🔲 Fresnel Lenses
  Lightweight lenses for beam shaping, solar, and illumination optics.

• 🔹 Freeform Optics
  Complex geometries for asymmetrical beam control and low-profile designs.

• 🛠 Opto-Mechanical Design
  Precision housing and alignment for injection-molded TIR modules.

• 🧪 Optical Metrology & Testing
  Beam profile evaluation, surface form error testing, and collimation accuracy.