Freeform Surface Machining Services – High-Precision Optical Fabrication

Freeform Surface Optics Machining Services

Ultra-Precision Fabrication for Optical & Photonic Innovation

When traditional optics can’t meet the demands of your system design, freeform surfaces open new possibilities. At Yighen Ultra Precision, we help clients across AR/VR, sensing, and photonics industries push boundaries with advanced freeform surface machining—achieving nanometer-level accuracy, tight tolerances, and real-world manufacturability.

Whether you're developing waveguides for AR headsets, complex beam-shaping optics, or custom HUD components, our freeform optics manufacturing workflow delivers results that are both optically and mechanically robust.

🧩 What Is Freeform Surface Machining—and Why It Matters

Freeform surface machining refers to the ultra-precision fabrication of non-rotational, non-symmetric optical geometries—surfaces that go beyond spheres, aspheres, or toroids.

These complex geometries offer several key advantages:

• Compact, folded optical paths

• Reduced component count

• Tailored beam redirection and aberration control

• High performance in off-axis systems

From AR waveguide optics to freeform reflectors for medical and automotive applications, this design freedom comes with high manufacturing demands. That’s where we come in.

“We often work with teams who’ve hit a wall with standard optics—and need surfaces that break symmetry without compromising quality. Our job is to turn those advanced geometries into buildable, testable, and repeatable components.”

At Yighen, we combine 5-axis CNC machining, SPDT (single-point diamond turning), and environmental metrology to produce optical surfaces with:

• Form accuracy down to ±0.2 μm

• Surface roughness below Ra 10 nm

• Verified dimensional stability across full-aperture parts

⚙️ Our Freeform Optics Machining Capabilities

All processes take place in fully climate-controlled labs—because at this level of precision, even a 1°C fluctuation can cause out-of-spec results.

Our team has designed and fabricated freeform optics for a range of demanding optical systems, including off-axis collimators, prism mirrors, curved waveguides, and more.

🧪 Real-World Applications & Case Scenarios

Freeform surface machining enables form factors and optical functions that traditional lenses simply can't achieve. A few of the systems we've supported include:

• AR/VR Optics – freeform prisms, combiners, and light guides for compact form factor headsets

• Automotive HUDs – curved projection mirrors with tailored eye-box alignment

• Laser Beam Shaping – refractive freeform elements for beam homogenization

• Imaging Systems – freeform-asphere hybrids for compact telecentric systems

• Custom Reflectors – architectural, medical, and surgical-grade illumination lenses

📸 Need sample images or simulations? We're happy to share past project visuals under NDA.

🔍 Why Choose Yighen for Freeform Surface Fabrication?

Freeform optics demand more than machine tools—they require an ecosystem of expertise, process control, and application understanding. We deliver:

✅ 10+ years of freeform optics experience across photonics, medical, and AR/VR sectors
✅ In-house tooling and fixture development to match each surface’s unique demands
✅ ISO 9001:2015-certified workflows for consistency and traceability
✅ Integrated metrology lab with white-light interferometry, CMMs, and custom inspection jigs
✅ Engineering support from design feasibility to final QA

“Yighen has helped us achieve geometries no other vendor could match. The delivered optics were precise, on-time, and met all spec requirements—with outstanding surface finish.”
— R&D Optics Lead, European Photonics Company

❓ Freeform Optics – Common Questions

Q1: What’s the difference between freeform and aspheric lenses?
Aspheric lenses are rotationally symmetric and correct spherical aberrations along the optical axis. Freeform surfaces break symmetry, allowing complex 3D beam shaping and off-axis imaging that aspheres can’t support.

Q2: How accurate are your machined surfaces?
Typical freeform optics we deliver meet ±0.5 μm form error and Ra < 10 nm surface finish. For high-performance systems, we can reach ±0.2 μm with custom calibration and metrology.

Q3: What design files do you accept?
We support STEP, IGES, STL, and native SolidWorks formats. Surface data with curvature maps or point clouds (ASCII or CSV) are preferred for complex geometries.

Q4: Can I send a prototype or test part?
Absolutely. We often run feasibility studies and initial prototyping to help clients verify manufacturability and performance before moving to full production.

🌀 Need Ultra-Precision Freeform Optics? We’re Built for It.

Whether you need sub-micron freeform mirrors, freeform prisms, or optical mold inserts, our ultra-precision machining platform is optimized for freeform surface generation.

With 5-axis diamond turning, CNC grinding, and in-house metrology, we ensure your freeform optics meet the tightest surface form and roughness specs.

🔵 Request a Freeform Optics Quote
📩 Share your drawing or spec—we’ll evaluate and respond within 24 hours.

Want to check our equipment capabilities and tolerances?
🧾 Download Equipment List & Machining Specs

Curious about our optical manufacturing team and background?
👥 Meet Yighen