Our Process Chain
From Design to Finished Product: Precision, Process Reliability, and Scalability
Uncompromising precision. Maximum reliability.
Scalable High-End Manufacturing for Micro-Optics
At INGENERIC, state-of-the-art automated processes are at the heart of our manufacturing operations. Across more than 10,000 m² of development and production space, we cover the entire micro-optics value chain – from optical design and the development of complex tooling systems to precision glass molding and all downstream back-end processes.
Our manufacturing environment includes 800 m² of ISO Class 6 and 8 cleanroom space designed for the production and finishing of high-quality optical components. In addition, 600 m² of climate-controlled precision areas provide ideal conditions for the most demanding machining processes. Strict temperature control within ±0.5°C ensures exceptional dimensional accuracy, process stability, and repeatability – critical factors in the quality of micro-optics and lens arrays.
By seamlessly integrating every process step, we meet the highest industry-specific requirements while ensuring efficient, stable, and future-ready production. The result is high-performance optical solutions that meet the most demanding technical specifications – reliable, scalable, and always at the forefront of technology.
1
Optical Design
At INGENERIC, every optical design begins with the specific application. Based on the application requirements, we either work from a customer-provided design or define the necessary specifications when only a general concept is available. In close collaboration with our customers, we develop customized optical and array geometries based on parameters such as radius, wavelength, power, coating, conic constants, and glass type. We then optimize the optical function to achieve the ideal beam path.
The next step is the technical drawing. We define specifications such as pitch, length, width, and array configuration, and establish all relevant tolerances. We achieve form accuracy of <1 µm PV, while design-dependent tolerances - such as center thickness - typically range from ±0.02-0.1 mm. This results in micro-optical components that are precisely specified, manufactured with high repeatability, and optimally tailored to the respective application.
The next step is the technical drawing. We define specifications such as pitch, length, width, and array configuration, and establish all relevant tolerances. We achieve form accuracy of <1 µm PV, while design-dependent tolerances - such as center thickness - typically range from ±0.02-0.1 mm. This results in micro-optical components that are precisely specified, manufactured with high repeatability, and optimally tailored to the respective application.
2
Tool Manufacturing
INGENERIC develops and manufactures customized precision forming tools that meet the demanding requirements of precision glass molding. Application-specific, temperature-resistant tool materials, including carbide and advanced ceramics, are processed using multi-axis ultra-precision grinding, lapping, polishing, and laser ablation.
To achieve sufficiently long service lives, the tools are coated prior to use with precious-metal or carbon-based coating systems. Tool design incorporates highly precise tolerance management, thermomechanical considerations, and the complex behavior of glass during forming. This enables stable series production with low scrap rates, while ensuring long-lasting tools, precise replication, and cost-efficient manufacturing.
To achieve sufficiently long service lives, the tools are coated prior to use with precious-metal or carbon-based coating systems. Tool design incorporates highly precise tolerance management, thermomechanical considerations, and the complex behavior of glass during forming. This enables stable series production with low scrap rates, while ensuring long-lasting tools, precise replication, and cost-efficient manufacturing.
3
Isothermal Precision Glass Molding
Isothermal precision glass molding is our key technology for the cost-efficient production of complex geometries in medium and high volumes. Optical functional surfaces are replicated directly onto the glass, achieving submicron form accuracy and surface roughness as low as 2–3 nm Rq. The process is suitable for a wide range of high-index glasses with outstanding optical properties and provides maximum design flexibility.
The technology is suitable for prototypes, sample production, and small batches, and can be scaled up to high-volume production. Wafer-level molding and multicavity molding enable the simultaneous replication of numerous optics in a single pressing cycle, while maintaining consistent precision and high productivity.
The technology is suitable for prototypes, sample production, and small batches, and can be scaled up to high-volume production. Wafer-level molding and multicavity molding enable the simultaneous replication of numerous optics in a single pressing cycle, while maintaining consistent precision and high productivity.
4
Coating
INGENERIC offers high-performance antireflection coatings for the spectral range from 400 to 2,100 nm. The coating systems are tailored to different high-index glasses, ensuring maximum transmission and long-term stability. We achieve this through glass- and application-specific coating designs, rigorous process control throughout the entire manufacturing chain, and comprehensive validation of optical performance.
In addition to AR coatings, mirror coatings, masks, and customized coating systems can be applied to INGENERIC micro-optics. These solutions are implemented in cooperation with qualified, long-standing partners to ensure consistently high coating quality and reliable delivery.
In addition to AR coatings, mirror coatings, masks, and customized coating systems can be applied to INGENERIC micro-optics. These solutions are implemented in cooperation with qualified, long-standing partners to ensure consistently high coating quality and reliable delivery.
5
Back-End Processes & Quality Assurance
INGENERIC’s back-end processing includes automated dicing, automated cleaning, surface inspection, precision optical assembly, and automated packaging for high-volume production.
Before shipment, every production batch undergoes comprehensive measurement and testing. These procedures range from precise form characterization and visual inspection to coating-quality verification. Highly accurate measurement systems, such as the Panasonic UA3P, enable reliable evaluation of complex optical surfaces in applications with the most demanding accuracy requirements. As a company certified according to DIN ISO 9001:2015, INGENERIC consistently complies with all relevant standard requirements. This ensures consistently high optical quality, process reliability, and dependable performance.
Before shipment, every production batch undergoes comprehensive measurement and testing. These procedures range from precise form characterization and visual inspection to coating-quality verification. Highly accurate measurement systems, such as the Panasonic UA3P, enable reliable evaluation of complex optical surfaces in applications with the most demanding accuracy requirements. As a company certified according to DIN ISO 9001:2015, INGENERIC consistently complies with all relevant standard requirements. This ensures consistently high optical quality, process reliability, and dependable performance.
Tailored Supply Chain Solutions for Industrial Needs
Benefit from “Made in Germany” manufacturing with end-to-end in-house process control for the highest levels of quality and delivery reliability. Supported by a strong partner and distribution network, INGENERIC ensures a dependable supply – even in volatile market conditions and in response to demanding industrial requirements.
This enables stable supply chains, maximum planning certainty, and sustainable production performance for your applications.
Get in Touch!
INGENERIC – Your Partner for Precision Optical Solutions
Do you have suggestions, specific requirements, or a concrete enquiry? We can help you select the right micro-optics for your application—from standard components to customised solutions. Please feel free to contact us for personal advice or an individual quotation.
We look forward to hearing from you!
