Micro Molding In Micro-Optic Manufacturing

Brett Saddoris, Technical Marketing Manager, Accumold

Micro-optics — including micro lenses, prisms, beam-splitters, and light pipes — are central to miniaturization in industries such as medical diagnostics, telecommunications, and augmented reality (AR). These components, often smaller than 1 mm or with micron-scale features, require extraordinary precision and consistency. Traditional methods like diamond turning and glass molding fall short in terms of cost and scalability. Micro injection molding, particularly as practiced by Accumold, offers a transformative alternative.

Accumold has pioneered the development of micro-optic molding through proprietary machinery, in-house tooling, and deep polymer science expertise. Their process enables sub-micron surface finishes and ultra-tight tolerances, crucial for demanding applications like medical sensors, fiber optic interconnects, and AR lens arrays. Case studies highlight how Accumold consistently delivers on projects requiring features under 100 microns and surface finishes within 50 angstroms — levels of precision unattainable with conventional methods.

The company’s strength lies in its vertically integrated model. By combining tooling, molding, metrology, assembly, and validation under one roof, Accumold reduces risk, compresses lead times, and enhances quality control. Their Design for Micro Molding (DfMM) approach ensures manufacturability from the start, reducing costly design revisions later.

Handling and assembly challenges are also addressed through automation, custom packaging, and over-molding strategies. This hands-free processing ensures quality and part integrity at scale.

As demand for micro-optics continues to grow, Accumold’s leadership in precision, scalability, and lifecycle support positions it as a key enabler of next-generation optical innovation — making the impossible not only possible, but mass-producible.