VIAVI offers large-volume injection molding of optical quality micro-optical elements.
The first step to start injection-molding components is the production of a metal master, usually nickel. VIAVI has mold tools for some specific part sizes. A custom mold tool may require 10-12 weeks lead time. Once the mold tool and metal master are available, material can be selected a process identified to establish the optimum production conditions followed by full-scale manufacturing.
A mold tool also needs to be built, which is usually the longest lead item and may require 10-12 weeks. We already has mold tools for a few specific part sizes such as 1in round and 2x2in square so that if a particular application requires this size one may skip building a new mold tool.
Once the mold tool and metal master are available it comes down to material selection and process development to establish the optimum production conditions followed by full-fledged manufacturing.