Injection Molding
We are a pioneer in polymer optics molding, blending over 30 years of expertise with advanced methodologies like Taguchi Design of Experiment (DOE), Window Processing, and Decoupled (Scientific) Molding to transform complex designs into functional optical masterpieces.
If You’re Looking For
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High-volume series production
Efficiently scales to meet large order quantities with consistent quality across batches.
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Integration of optical and mechanical functionality
Harmonizes optical components with mechanical structures to enhance device performance and usability.
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Consistent part-to-part repeatability
Ensures every product is virtually identical, maintaining strict quality and precision across all units.
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High precision to cost ratio
Delivers exceptionally precise products at a competitive price point, maximizing value for customers.
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Rapid production of precision polymer optics
Quickly manufactures high-precision polymer optics to meet tight deadlines without compromising quality.
Then Injection Molding is the perfect fit for you!
Clean Production
ISO 7 (Class 10k) cleanrooms ensure a contamination-free environment
Versatile Capacity
Machines with clamp forces ranging from 20 to 300 tons
Controlled Climate
Complete climate control for optimal production conditions
Advanced Lens Removal Robotics
Equipped with 3-Axis and 2-Axis robotics for precise lens handling and efficient sprue removal
Quality Control Operations
Cosmetic inspections, cavity separation, precise packaging, and robust assembly processes
Tooling
Optics molding demands precision far beyond standard injection molding.
We provide tolerances within millionths of an inch to meet the exacting standards expected by our customers.
New Molds
In House Mold Design & Build
At Diverse Optics, quality in injection molding is paramount, which is why we fabricate all molds in-house. Our rigorous process guarantees each production mold is engineered to consistently produce up to a million high-quality optics. It begins by understanding each client’s specific needs, followed by a comprehensive review by our expert team to ensure performance. With over 35 years of experience creating hundreds of molds, our engineers have a deep understanding of the most effective techniques. Our mold makers ensure we meet our clients’ standards for quality, delivery, and value through detailed mold design reviews, mold flow analyses, and frequent updates.
Design Review and Tool Fabrication
The design phase involves meticulous reviews and refinements of both 3D and 2D tool designs until they meet our high standards. Upon client approval, we proceed with tool fabrication, prioritizing early delivery of critical components like optical pins and inserts. This allows us to begin working on the optical surfaces early in the build process, ensuring all parts are assembled, inspected, and ready for mold trials simultaneously, facilitating a smooth transition to production.
Interested in Injection Molding?
Speak to an Expert Today!
We want to know your needs exactly so that we can provide the perfect solution. Let us know what you want and we’ll do our best to help.
Society of Plastics Industry (SPI) Tooling Classifications
The Society of Plastics Industry (SPI) Tooling Classifications define standards for the durability and production capacity of molds used in plastic manufacturing. Diverse Optics adheres to these classifications to ensure optimal quality and lifespan for their molds
Class 101 Mold
Guaranteed for 1,000,000 + cycles
Ideal for extremely high production demands and are crafted from the highest quality materials to ensure durability and reliability.
Class 102 Mold
Guaranteed for 1,000,000 cycles
Suited for medium to high production levels and are robust enough to handle abrasive materials and demanding tolerances.
Class 103 Mold
Guaranteed for 500,000 cycles
These molds cater to low to medium production needs, balancing cost and performance effectively.
Class 104 Mold
Guaranteed for 100,000 cycles
These molds are intended for lower production volumes, offering a moderate price point for limited runs of non-abrasive materials.
Class 105 Mold
Guaranteed for 25,000 - 50,000 cycles
These molds are primarily used for prototype development and light production, providing an economical option for small batches.
Acceptance of Customer
Transferred Tooling
At Diverse Optics, we offer a specialized service known as transfer tooling, where we welcome customers to bring their existing molds from other suppliers. Unlike the unpredictable nature of using diverse molds, which can often result in quality inconsistencies, our expertise in precision polymer optics ensures that each mold is thoroughly evaluated and optimized for high-performance output.
When molds arrive, we conduct a detailed assessment to understand their current condition and identify any necessary enhancements. This evaluation includes documenting the mold's state with digital imagery and assessing its capabilities against your specific optical requirements. Based on this analysis, we recommend and implement on-site improvements to ensure the mold meets our stringent production standards.
Our depth of knowledge in polymer optics molding extends beyond basic injection molding techniques. We understand the intricate requirements of optical systems—from laser collimation and imaging to illumination—allowing us to refine and adapt molds for superior functionality. Bring your challenging molds to Diverse Optics, and let our expert team transform your production challenges into success stories.
Ensuring Longevity & Optimal Performance
Preventive maintenance is not just a part of our business—it's a cornerstone. By diligently maintaining your molds, we ensure smoother operations and extend their lifespan, which in turn facilitates the seamless production of millions of high-quality polymer optics. A well-maintained mold operates flawlessly, enhancing consistency and reducing production challenges. Conversely, neglecting mold care can lead to operational difficulties, introducing inconsistencies and variations that compromise product quality. Our commitment at Diverse Optics is to keep your molds performing at their best, maximizing both performance and durability through comprehensive and proactive maintenance.
Comprehensive Care for Optimal Mold Functionality
Diverse Optics is equipped with advanced tools like CNC and conventional milling machines, surface grinders, EDM, and lathes to ensure precise, real-time adjustments during mold trials. This setup guarantees rapid startup and strict adherence to delivery schedules.
Our "Evergreen" service demonstrates our dedication to maintaining your molds in optimal condition. It includes regular preventive maintenance, emergency repairs, and comprehensive upkeep according to industry standards. Through this service, we ensure your molds remain functional and efficient throughout their lifecycle, minimizing downtime and extending durability.
Proactive Measures for Uninterrupted Production
At Diverse Optics, risk prevention is fundamental to our polymer optics operations. We begin with a robust preventive maintenance program to keep your molds in peak condition, ensuring they are always production-ready. However, manufacturing realities mean that sometimes, even the best-prepared plans face unforeseen issues.
Understanding that risk tolerance can vary based on the customer's specific industry and budget, we offer tailored risk management strategies. These include comprehensive risk assessments and a variety of mitigation options to match your needs. Options may range from maintaining a strategic inventory to ensure continuous supply, utilizing diamond turning for precise optics production, keeping critical spare mold components on hand, or even creating a complete backup mold for critical projects. Our goal is to provide peace of mind, ensuring your operations run smoothly no matter the circumstances.