25 Years of Change in Optical Manufacturing and Product Specs Manufacturing optics has seen extensive developments over the last 25 years. In the past, optical manufacturing relied heavily on manual processes and standardization. Customization was difficult, and optical parts were typically produced with high tolerances. Today, techniques such as nanotechnology, additive manufacturing (3D printing) and CNC manufacturing enable us to custom produce precision optics with almost any geometry desired. What does this mean in practice? Let’s take a closer look at the evolution of manufacturing in two specific product lines: aspheric lenses and microscope objective lenses. Advances in Optical Manufacturing: The Aspheric Lens Aspheric lenses are lenses designed to eliminate spherical aberrations, coma, field distortions, and astigmatism, among other aberrations. They have a non-spherical profile and focus light to a small point. 25 years ago the manufacturing of aspherical lenses was an extremely expensive undertaking, but today we can produce these lenses at scale and at a price point that makes them affordable for applications across industry, research, medicine, and defense. Today, aspheric lenses are included even in consumer products. Optical advances mean that today we can produce high quality aspheric lenses at a better price point than ever before. What made the difference? Changes in manufacturing technology, advances in materials, and innovations in computational design were all part of it. Modern materials such as plastics and advanced optical glasses not only provide high optical qualities like reduced chromatic aberrations, they are, in some cases, easier to form into non-spherical optics. Plastics, for instance, lend themselves well to molding and can thus be shaped into any aspherical form desired. New Manufacturing Techniques like computer controlled precision polishing enable us to perfect even the most intricate aspheric shapes. Other manufacturing techniques like advanced glass molding and injection molding have seen vast improvements over the past two decades. This new new fine control of the manufacturing process enables us to produce miniature aspheres as well as custom pieces created to our customers’ exact specifications. Innovations in Computational Design allow our optical designers to calculate the ideal geometry for an asphere given required specifications and application notes. Advances in Optical Manufacturing: Microscope Objective Lenses Microscope objective lenses are the optical centerpiece of the microscope. They consist of a multi-lens assembly and are placed so as to accept light emitted by the object (specimen) being imaged. Perhaps not surprisingly, the objective lens is the most difficult part of a microscope to design and produce, and the quality of the final image is directly related to the quality of the objective. Microscope objectives have seen innovations in materials, design, and manufacturing technology over the past 25 years Microscope objective lenses can be produced with increased numerical aperture and increased magnification when compared to 25 years ago. Examples of these in use include ultra-high resolution objectives for applications like STED (Stimulated Emission Depletion) microscopy and PALM (Photo-Activated Localization Microscopy.) Just as we saw when we looked at the evolution of aspheric lenses, improvements in objective lenses have been driven by three key factors: advances in materials and manufacturing technology and innovations in design. Modern materials used in microscope objectives include advanced substrates like fluorite glass. Many modern objectives also feature enhanced optical coatings, which minimize optical aberrations, reduce light loss and increase contrast. This enables the microscope to produce images that are sharper and more vibrant, even under high magnification. Design innovations include the refinement of flat-field corrected objectives as well as immersion lens systems. We’ve become adept at creating smaller, more compact objective lenses that perform better than the bulky system of yesterday. These lenses may be designed with the special needs of fluorescence and confocal microscopy in mind, enabling them to be used for high contrast imaging of living cells. Advances in manufacturing technology enable us to produce high quality objectives in a more efficient, cost-effective manner than before, and to conduct extensive automated quality controls on each piece before it is assembled into the final objective. This is only a small survey of some of the advances we’ve seen over the past twenty-five years. If you’d like to find out more, have a look at our article on how optical innovations like these are fueling technological change. References Blom, H and Widengren, J. Stimulated Emission Depletion Microscopy. Chemical Reviews 2017 117 (11), 7377-7427. Singh, R., and Chen, Y. “Comprehensive advancements in automatic digital manufacturing of spherical and aspherical optics,” Proc. SPIE 12769, Optical Metrology and Inspection for Industrial Applications X, 127690B (27 November 2023); Spring, Keller, & Davidson. Microscope Objectives Introduction. Evident Scientific, Yin, S., Jia, H., Zhang, G. et al. Review of small aspheric glass lens molding technologies. Front. Mech. Eng. 12, 66–76 (2017). Related content