FROM MOLD TO INJECTION: HOW AN ENDOSCOPIC LENS IS MADE
In medical imaging, the endoscopic lens is the core element that defines clarity and accuracy. Though only a few millimeters in size, its production involves one of the most demanding optical manufacturing chains.
In medical imaging, the endoscopic lens is the core element that defines clarity and accuracy. Though only a few millimeters in size, its production involves one of the most demanding optical manufacturing chains.
Mold: The Foundation of Precision
Every lens begins with optical design, where resolution, field of view, and distortion control are defined. These parameters are translated into surface data, then replicated by the mold.
Optical molds differ from standard molds:
Surface roughness below 10 nm
Shape accuracy within sub-micron levels
Because of these requirements, molds are often more valuable than the lenses they produce.
Outsourced Processing
Many companies outsource mold inserts to specialized suppliers. Ultra-precision equipment such as Single Point Diamond Turning (SPDT) machines and interferometers are costly, and expertise takes years to develop.
Typical workflow: rough machining in-house, precision machining and surface finishing outsourced, followed by assembly and validation internally. This balance reduces costs while ensuring quality.
Why Nickel Plating Matters
Nickel plating is critical for optical molds:
Durability: Higher hardness resists wear during injection.
Stability: Protects against oxidation and corrosion.
Optical quality: Easier to polish to Ra < 10 nm.
Repairability: Damaged molds can be re-plated and restored.
Without plating, molds degrade quickly; with plating, they can last millions of cycles.
Optical Injection Molding
Optical injection molding machines must operate with extreme control:
Mold temperature variation < 1°C
Cleanroom environment to avoid dust and bubbles
Stable clamping force for consistent dimensions
The process includes resin drying, injection, packing, cooling, and automatic demolding. Each lens is validated through interferometry, MTF testing, and surface inspection.
Post-Processing and Assembly
Lenses receive multi-layer AR coatings to maximize transmission. Several lenses and spacers are then aligned into compact modules. Cleanroom packaging ensures reliability for medical use.
Conclusion
The birth of an endoscopic lens is a precise journey: from ultra-accurate mold design, to nickel-plated durability, to controlled injection molding and coating. Each step ensures physicians can rely on crystal-clear imaging in critical procedures.
At Aubor Optoelectronics, we believe optics is not just manufacturing—it is precision with responsibility.
