Optical Prototype Services
Prototype Optics Assemblies - Built for Production
At Clear Align, we specialize in prototype optical assemblies that are designed with production in mind. Our approach is simple: we only develop prototypes that we can later manufacture at scale. This ensures every design transitions smoothly from early builds to volume production, reducing risk and keeping your customer’s timeline on track.
Because our teams manage the full optical prototyping process—from design through optical fabrication to coating to assembly - we can move faster. In today's fast-paced optics industry, the necessity of rapid prototyping is clear for staying competitive and meeting evolving customer needs. While not “instant,” our process is efficient, reliable, and built around delivering quality systems that scale, with a strong focus on decreasing development cycles to meet market demands.
Delivering True Rapid Prototyping
We focus on delivering rapid prototyping without compromising manufacturability. Every optical prototype is engineered for performance, tested for reliability, and aligned with future production needs.
Our capabilities include:
- EO/IR and thermal optical systems
- High-precision lens assembly and subsystems
- Prototypes of critical optical components including imaging optics, mirrors, prisms and specialty optics
- Rapid prototyping for optical instruments and platforms
By integrating optical design, mechanical design, coatings, and assembly under one roof, we quickly create solutions that meet mission needs while supporting long-term production.
We offer a range of resources to support rapid prototyping and help accelerate your product’s time-to-market.
Materials and Applications in Optical Prototyping Solutions
Selecting the right materials is a cornerstone of manufacturing of lens for prototyping. Our optics manufacturing rely on a range of over 200 materials including optical crystal materials and over 30,000 coatings fixtures. Whether a diffractive lens with a custom bandpass filter or mirror, we can help.
Rapid optical prototyping techniques, including CNC machining and diamond turning, empower teams to efficiently produce complex components—such as lenses, mirrors, and prisms—at such lightning speed. By optimizing material selection and manufacturing processes, companies can reduce development cycles and help faster customers bring innovative products to market with confidence.
Advanced Optical Manufacturing Processes with In House Tooling Solutions
We deliver true rapid prototyping from optical components and specialize in infrared optics. Techniques like 5-axis CNC optical machining, single-point diamond turning, and conventional polishing and grinding in house enable highly complex optical prototypes for different solutions.
We reduce lead time and cost compared to traditional optical lens manufacturers that lack unique geometries and features that are critical for optimal optical performance. The result is a streamlined path from prototype development to mass production, ensuring that every optical system is ready for demanding applications.
Testing and Validation for Performance of an Optical System
Comprehensive testing and validation—using techniques such as optical characterization, interferometry, MTF testing, testing with infrared laser light and spectrophotometry.
Through rigorous testing, any issues or defects can be quickly identified and addressed, enabling the design and manufacturing process to be refined for optimal results. This approach not only accelerates the development cycle but also reduces costs by minimizing the need for rework or redesign.
Advanced testing and validation techniques are especially important in applications where reliability is critical, such as imaging and spectroscopy. By thoroughly evaluating prototypes, engineers can ensure that the final optics deliver the required functionality and performance, supporting the success of projects across a wide range of industries.
Quality Control and Assurance
Ensuring that prototypes meet stringent AS9100, ISO900, ITAR and MIL standards is critical. Quality control and assurance are fundamental. Our robust quality process—encompassing inspection, testing, and certification—ensures the highest standards for reliability for your application whether lenses for lasers or an optical mirror for space telescopes.
By combining advanced manufacturing, thorough testing, and rigorous quality control, optical prototyping support customer success.
Vertical Integration Opto-Mechanics - Classic Optical Laboratories
Clear Align’s vertical integration means:
- Rapid optical prototyping linked directly to production capabilities wth
- Prototypes designed to minimize rework and troubleshoot issues early
- Ability to develop prototypes that are tied to our optical lens manufacturing to better reduce element count and improved optical precision optics
- optical lens manufacturer with custom optical filter, band pass filter, beamsplitter or optical thin film coatings with unique broad band or multi band optical coatings
- Shorter lead times
For low-volume or prototype optics, grinding, polishing and single point diamond turning provide quick answers. Our goal is to help customers move faster on custom solutions ready for scale. In house CNC metal machining is also a plus.
From Prototype to Success
Every prototype we deliver is backed by in-house manufacturing expertise as a leader in the photonics industries. New technologies are constantly being introduced in the optics and imaging industry, requiring rapid adaptation in prototyping. To stay competitive, it's essential to bring innovative solutions to market.
Aerospace, Defense and Commercial Optics Technologies We Have Delivered to Customers
Imaging & Sensing Systems
- EO/IR payloads – MWIR, LWIR, SWIR, and multispectral systems
- Thermal cameras – zoom and fixed-field designs for airborne and spaceborne use
- Wide-field and narrow-field imagers – including helmet-mounted displays and gimbaled systems
- Hyperspectral optics – for target identification and spectral analysis
- Rangefinders and laser receiver modules – integrated into aerospace platforms
Laser Application & Directed Energy Optics
- Laser optics and beam expanders for targeting and communication
- Free-space optical communication devices for satellite and aircraft links
- Interferometers, illuminators, and LIDAR subsystems
- Space-qualified optical telescopes adn assemblies built for radiation, vibration, and temperature extremes
Structural & Environmental Integration for Your Sourcing Requirements with Fast Lead Time
- Optomechanical assemblies – ruggedized housings for space and flight
- Lightweight optics designed to reduce element count for size, weight, and power (SWaP) optimization
- Optical benches and assemblies engineered for vibration, shock, and thermal cycling
If you have sourcing requirements and need a partner who can develop a few prototypes or a single part today and anufacture them tomorrow, Clear Align provides the experience, process, and integration to make it happen.