Avantier specializes in freeform optics and free?form optics solutions that push the limits of optical performance while reducing system size and complexity. Our custom freeform optics design and manufacturing services support imaging, sensing, and laser systems in industry, defense, research, and medicine, from one?off prototypes to high?volume production.

Freeform Optical Manufacturing Processes

Because freeform optics lack rotational symmetry and are not referenced to a simple base sphere, traditional grinding and polishing methods are not sufficient. Avantier relies on state?of?the?art CNC optical grinding and ultraprecise single?point diamond turning to shape freeform surfaces directly from the design model.

A typical freeform optics manufacturing workflow includes:

• Rough shaping of the freeform surface from an optical blank using CNC?integrated grinding and diamond turning based on CAM?defined surface data.?
• Iterative rough and fine grinding with CNC?controlled tools, combined with frequent profile measurements to identify and correct shaping errors.?
• Sub?aperture polishing tailored to complex freeform geometries, followed by multiple metrology checks using surface profilers, interferometers, and computer?generated holograms to ensure the optic meets specification.

Depending on the substrate, some free?form optics are also produced via precision molding and then refined with CNC polishing, especially for metal and plastic freeform lenses and mirrors in higher volume applications.

Custom Freeform Optics Design & Manufacturing Solutions

Avantier’s optical engineers and designers have extensive experience in freeform optics design, tolerancing, and integration into real?world imaging and beam?delivery systems. The team can start from a full freeform optical design, an initial concept, or a list of performance requirements and then co?develop a manufacturable freeform solution.

Services include:

• Freeform optics design and optimization for imaging, illumination, and laser applications.
• Prototype?to?production scaling for free?form optics in industrial, defense, medical, and research programs.?
• Close collaboration on opto?mechanical integration, alignment strategies, and coating choices tailored to each freeform optic.

Avantier provides end?to?end freeform optics and free?form optics solutions, combining design expertise, advanced CNC manufacturing, precision molding, and rigorous metrology to deliver high?performance custom components. Whether you need a single prototype or a volume production run of freeform optics for imaging, sensing, or laser systems, the team is ready to support your project.

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