Optical Design
Versatile Applications Across Industries
Medical, laser, sensing, automation, and research fields fully supported
Engineering-Oriented Thinking
Focused not only on theory but also on manufacturability and cost control
Experienced Team
Years of cross-industry lens design experience with deep knowledge of multi-platform integration
Rapid Turnaround
Initial optical design drafts can be delivered in as little as one week depending on project schedule
Optical Design
Hobbite offers one-stop optical design services, covering the full spectrum from optical path modeling and lens design to application-specific development. Our goal is to help clients enhance product performance, optimize system structure, and shorten development cycles. Whether you’re at the early concept stage or already have clear specifications, we provide professional and reliable support.
Frequently Asked Questions (FAQ)
Optical design primarily addresses the following issues:
- Low optical efficiency and high energy loss
- Blurred imaging, significant aberrations, and insufficient contrast
- Inaccurate beam control or interference from stray/reflected light
- With optimized optical layouts and parameter calculations, the system’s overall performance can be significantly improved to meet more demanding application scenarios.
Rest assured, no technical background is required. The Hobbite team will guide you in clarifying goals, interpreting technical specifications, and providing comprehensive support throughout the entire journey. Our custom optical design services are transparent, accessible, and specifically tailored for product managers, project engineers, and startup teams.
Optical design applies to imaging systems, laser systems, communication modules, medical devices, research instruments, and more. Whether your need is a lens design for a precision optical system or a cost-effective solution, we tailor our designs to meet specific industry requirements.
Customization Process
Each component of the overall optical lens design framework can be further broken down, and the lens design process is completed step by step through this level-by-level decomposition and accessibility assessment. During the design process, it is necessary to balance various indicators to avoid optimization stagnation.
Requirements and Specifications
The first step in optical design is to enter requirements and break down specifications. Different lens types require different design specifications. Common specifications include focal length, field of view, operating wavelength, f/number, image height, resolution, distortion, and transmittance. During this phase, your design engineer will work closely with you to clarify performance goals and system constraints.
Initial Structure
The rationality of the initial structure directly impacts the efficiency of subsequent optimization. An initial optical structure allows for rapid convergence and facilitates aberration control; a poor structure, however, can cause optimization to become trapped in a local minimum.
There are three common approaches to obtaining the initial structure:
- PW method: Suitable for theoretical research and complex systems, but with a longer design cycle.
- Literature or patent reference: This method, through focal length scaling or parameter adjustment, can yield relatively mature structural solutions and is a common and efficient method.
- Parallel plate optimization: Relying on extensive experience, starting from a simple optical path, the optimal structure is obtained through optimization.
Common lens initial structures include double-Gauss, telephoto, reverse telephoto, telephoto, and projection configurations.
Optical Aberration Analysis
Common aberrations in optical systems include spherical aberration, coma, astigmatism, field curvature, distortion, and chromatic aberration. The effects of these aberrations can be effectively reduced by properly allocating focal power, adjusting the aperture position, and employing aspheric or cemented lens designs. Spherical aberration and coma can be corrected using apertures and aspheric lenses, astigmatism and field curvature can be optimized through focal power separation, and distortion and chromatic aberration can be balanced through symmetry or cemented structures. For example, in a reverse telephoto lens, multiple lens groups work together to correct aberrations, ensuring image clarity and system telecentric stability.
Tolerance Analysis and Processability Evaluation
Tolerance analysis in software like Zemax can be divided into two categories:
- Surface tolerances: such as radius of curvature, center thickness, tilt, and eccentricity.
- Component tolerances: such as assembly clearance, spacing, and positioning errors.
Key Principles:
- Surface tolerances must be fully communicated to ensure both performance and processability.
- Component tolerances should be appropriately relaxed to ensure ease of assembly and meet design objectives.
Ghost Image Assessment
Stray light analysis aims to assess the path and energy threshold for ghost image formation within a system. Commonly used software includes ASAP and TracePro. If simulation results indicate that ghost image energy exceeds the specified threshold (e.g., <10⁻⁶ for mobile phone lenses and <10⁻⁵ for spectrometers), the optical system needs to be recalibrated or the coating transmittance needs to be improved.
Drawing and Testing
Based on the final optical design results, 2D drawings are created, including component and assembly drawings. These drawings must adhere to optical drawing specifications:
- Hole-shaft fit
- Negative tolerance for outer diameter
Complete optical parameters and tolerance requirements must be specified. This stage also requires consideration of mechanical structure, assembly space, and inspection methods to ensure the design is manufacturable.
Design Completed
Once the optical design is complete, a comprehensive report must be generated, including:
- Optical system diagram
- Imaging and aberration analysis results
- Tolerance and stray light analysis
- Processing and assembly recommendations
Once the above steps are completed, the complete optical design process from requirements to manufacturability is achieved.
Optical Design Solutions
Optical Path Optimization
Using geometric optics and ray tracing simulation, we refine beam propagation paths to reduce unnecessary reflections, refractions, or energy losses. This custom optical design approach is ideal for laser processing systems, optical communication setups, and other light-efficiency-critical applications.
Imaging Quality Enhancement
By designing lens combinations, adjusting aperture positions, and controlling aberrations, we improve image resolution, contrast, and edge clarity. This type of lens design is widely used in laser projection, endoscope systems, and machine vision applications.
Custom Light Field Control
For specific illumination shapes or energy distributions—such as uniform lighting, focusing, ring shapes, or line sources—we develop optical structures and corresponding components like freeform surfaces, cylindrical lenses, and microstructures. These custom optical design solutions meet precise requirements for beam shaping and uniformity.
Technical Support & Ongoing Optimization
Collaborative Service Model
Beyond just providing solutions, we build strong communication channels with your R&D team, offering ongoing support to ensure the custom optical design implementation runs smoothly and is fine-tuned to its optimal state.
Long-Term Performance Tracking & Upgrades
Based on your usage feedback and evolving market trends, we continuously improve the original optical design—whether it’s new materials, expanded wavelength ranges, or enhanced system compatibility—ensuring your products remain at the forefront of optical innovation.