Case Studies

See how our precision optical components solve real-world challenges across industries

Medical Devices

High-Precision Lens Assembly for Surgical Microscope

European Medical Equipment Manufacturer

Challenge

A European medical equipment manufacturer needed custom plano-convex lenses with surface accuracy better than λ/8 and centration under 1 arc minute for their next-generation surgical microscope. Their existing supplier could not consistently meet these tolerances at volume.

Solution

PhotonEdge provided UV Fused Silica plano-convex lenses with λ/10 surface accuracy, <30 arc second centration, and custom AR coatings (R<0.25% @ 450-700nm). Each batch included full interferometer and spectrophotometer test reports.

Result

λ/10 Surface accuracy achieved
100% Inspection pass rate
3 weeks Lead time (vs. 6+ weeks previous)
Laser Systems

High-Power Laser Mirror for Industrial Cutting

North American Laser Systems Integrator

Challenge

A laser systems integrator required high-energy laser mirrors with damage threshold exceeding 15 J/cm² at 1064nm, 10ns pulse. Their previous mirror supplier had inconsistent coating adhesion, causing premature failure under high-power conditions.

Solution

PhotonEdge supplied H-K9L(BK7) substrate laser line mirrors with e-beam deposited dielectric HR coatings. Each mirror was laser damage tested and came with spectral curve documentation. Custom beveling (0.25mm×45°) prevented edge chipping during mounting.

Result

>20 J/cm² Laser damage threshold achieved
R>99.8% Reflectivity at 1064nm
0 failures In 12 months of field operation
Scientific Research

Custom CaF2 Windows for UV Spectroscopy

University Research Laboratory

Challenge

A university spectroscopy lab needed CaF2 windows with exceptional UV transmission (T>93% at 200nm), surface quality 20-10 scratch-dig, and precise wedge angle (<30 arc seconds) for their vacuum UV spectrometer. Standard catalog windows could not meet these combined requirements.

Solution

PhotonEdge manufactured custom CaF2 windows with 20-10 surface quality, λ/8 flatness, parallelism <30 arc seconds, and no anti-reflection coating (to preserve broadband UV transmission). Each window was individually tested with UV-VIS spectrophotometer and Zygo interferometer.

Result

T>94% UV transmission at 200nm
20-10 Surface quality achieved
2 weeks Delivery for first prototype batch
Defense & Aerospace

IR Optical Assembly for Thermal Imaging

Defense Contractor

Challenge

A defense contractor required Germanium and ZnSe optics for a long-wave infrared (LWIR) thermal imaging system. Components needed to meet MIL-SPEC environmental requirements including thermal cycling (-40°C to +70°C) and humidity resistance while maintaining optical performance.

Solution

PhotonEdge supplied Ge aspheric lenses and ZnSe windows with DLC (Diamond-Like Carbon) coatings for environmental protection. Full environmental testing reports and material certifications (conflict-free mineral sourcing) were provided with each shipment.

Result

T>95% LWIR transmission achieved
MIL-SPEC Environmental compliance verified
5+ years Ongoing supply partnership

Have a Similar Challenge?

Our optical engineering team can help you find the right solution. From custom specifications to volume production, we deliver precision optics that meet your exact requirements.

Request a Custom Quote
Chat with us