Precision Glass Molding
What Can You Do in 80 Seconds?
In 80 seconds…
⬢ Joey Chestnut can eat at least 13 hot dogs
⬢ Max Park can solve a Rubik’s Cube at least 16 times
⬢ A Falcon 9 rocket has already broken the speed of sound
At Hexagon Optics, we can make a glass aspheric lens every 80 seconds!
How We Do It
Hexagon Optics uses modern progressive Precision Glass Molding (PGM) machines and are currently the only company in the United States operating this technology.
Progressive precision glass molding divides the lens manufacturing process into 8-10 precisely controlled stages including heating, forming and cooling. Rather than completing the process in a single step, each stage performs one optimized function. This approach delivers significantly higher throughput and consistency compared to conventional methods. While the total cycle time for an individual lens may not be shorter, the efficiency of the staged process allows a finished lens to be produced every 80-90 seconds.
Scaling What’s Possible, Not Just Small Lenses
Today, Hexagon Optics can mold precision glass aspheres up to 45+ mm in diameter, enabling high-resolution imaging across industrial, medical, defense and scientific applications. With even larger-diameter molding capability planned for next year, we continue to expand the boundaries of molded optics, giving our customers greater design freedom, higher performance and a clearer path from prototype to full-rate production.
Aspheric Lenses
Hexagon Optics takes a modern approach to precision glass molded aspheres. Our state-of-the-art progressive molding machines deliver high-quality aspheres with exceptional consistency. Designed for high-volume production yet adaptable for low-volume runs, they give customers unmatched flexibility in scaling their designs.
Ball Lenses and Preforms
Hexagon Optics supplies high-quality ball lenses and preforms through our extensive global supply chain. They are available in a wide range of optical materials, including specialty glasses such as chalcogenide, fused silica, and ruby. Sizes range from 0.4 µm up to 15 mm or larger, suitable for nearly any application. With exceptional surface quality (Ra = 1.2 nm, visual 10/5 Scratch/Dig achievable), our lenses enhance signal coupling between emitters, fibers, transmitters, receivers, and detectors.
Optical Molds and Tooling
We supply state-of-the-art optical molds manufactured from advanced materials such as binderless tungsten carbide, CVD silicon carbide, nickel-plated stainless steel, and specialized alloys. Our molds support highly complex geometries, including aspheric, asphero-diffractive, freeform, Fresnel, and other non-traditional forms.
We also offer a full range of high-performance mold coatings, from noble metals like Platinum Iridium to advanced diamond-like carbon (DLC) coatings, specifically tetrahedral amorphous carbon (ta-C).
More than 2 or 3 Materials to Choose From
There are over 200 optical glass formulations developed specifically for precision molding. These materials are designed to maintain high optical performance while reducing manufacturing costs. While many traditional optical glasses can be molded, they were not engineered for the process, often resulting in higher tooling wear, longer cycle times, and reduced process stability. Moldable glasses, in contrast, are optimized for lower processing temperatures, extended mold life, and improved production throughput.
A common misconception is that moldable glasses are inherently softer or lower performing. While this can be true for certain compositions, many moldable formulations offer equal or greater hardness and durability compared with conventional glasses, while still delivering comparable refractive and dispersion properties. In addition to a broad portfolio of moldable oxide glasses, Hexagon Optics also supports radiation-resistant glasses and chalcogenide materials for infrared systems.
Material selection is one of the most critical decisions in any optical design. Our team maintains an extensive library of glass formulations, and qualifying a new material we have not previously molded is fast and cost-effective. If you need guidance navigating the options, our engineers are ready to help you select the optimal glass for your application.
Partnering for Performance, Scale and Innovation
Hexagon Optics provides precision glass molded lenses designed for laser collimation, IR imaging, and other demanding applications. Instead of offering a fixed catalog, we work directly with you to understand your specific requirements and deliver lenses that meet your exact performance needs. Tell us what you’re looking for, and our team will help you achieve the right solution.
Reach out to learn how Hexagon Optics can support your glass molding projects