Injection moulding of optical components | Plastic lenses & LED optics

Perfect optics: the key to light quality

Energy-efficient, high luminous efficacy and a long service life: LEDs are the ideal light source. And thanks to their many advantages, LED lighting is suitable for a wide range of applications in all kinds of environments. The light emitted by the LEDs is directed by small lenses, which determine the direction and distribution of the light output.

De Beer Plastics manufactures lenses for various types of LED lighting. These lenses, also known as optics, play a key role in determining the quality and light distribution of LED lighting. As such, these seemingly simple components are the most important factor in the quality of an LED lamp.

The challenge of an optician’s shop

The injection moulding of optical components (lenses) for the lighting industry is a specialist field that requires a great deal of knowledge and experience. Each lens must be positioned in exactly the right place in front of the LED, which demands extreme precision throughout the entire product.

But it is precisely the specific characteristics of optical components – a thin sheet containing dozens of lenses that are many times thicker – that run counter to the ‘laws of injection moulding’, where the aim is always to achieve uniform wall thicknesses.

Precision for every lens

Thanks to MoldFlow analyses, but above all to our many years of experience, we are able to shape even the most complex geometries with precision down to the hundredth of a millimetre. The polishing of the lenses is a traditional craft and is carried out entirely by hand.

By using 3D scanning, we can ensure that, in the case of optical assemblies with many lenses, the first lens matches the last lens exactly, with tolerances of just a few hundredths of a millimetre. We aim to get it right first time, but sometimes several iterations are needed to create the perfect product.

Materials for optics

The specific application largely determines which material is most suitable. Many standard optical components are made from PMMA, which is renowned for its exceptional transparency. However, there are applications where PMMA does not perform well, such as in lamps containing high-power LEDs that generate a lot of heat. In such cases, polycarbonate (PC) is often a suitable alternative.

De Beer Plastics processes various grades of PMMA and PC, as well as a range of specialist materials for optical applications. As we are not limited to just a few materials, you can rest assured that together we will find the best material for your optical application.