LENSEL OPTICS PVT. LTD. ISO 9001:2008 Certified Company
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2 BRIEF INTRODUCTION OF LENSEL OPTICS We have a Glass Lens Manufacturing Line, Plastic Injection Molding Line, Coating Systems, Optical Assembly facilities and Test and Inspection facilities at our factory site in Pune, India. Around 80% of our Sales Turnover is from Contract Manufacturing and over 50% of our Sales are from overseas Customers. We have supplied Glass Optics, Plastic Optics & complete optical assemblies to customers in USA, UK, Canada, Belarus, Australia, Brazil, Israel, Belgium, France, Egypt, Columbia and various other countries. We supply lenses for use in defence, medical and consumer applications. Lensel has 57 employees including an Optical Engineer, 2 Mechanical Engineers, 35 skilled workers. Most of our skilled workers have been with us for over 10 years. Lensel has a current Annual Sales Turnover of Rs 70 Million, and has grown by 300% in the last 6 years. We are continuing to grow strongly and expect to reach Rs 100 Million Turnover in next 2 years.
3 HISTORY OF LENSEL Lensel Optics was founded in 1979 by Mr. S. D. Rege. He was joined in 1981 by his cousin, Mr. S. M. Rege. Lensel started with the Compression Molding of Plastic Fresnel Lenses for use in Overhead Slide Projectors. From 1979 to 2005, Lensel was primarily in the Overhead Projector field supplying various Overhead Projector Components. As the Overhead Projector became obsolete, Lensel diversified into Glass Optics, Plastic Injection Molded Optics, Contract Manufacturing of Glass and Plastic Optics assemblies and AR Coatings. In 2008, having completed his BS & MS in Optical Engineering from the University of Arizona and after working in the US for 4 years, Mr. Sid Rege (son of Mr. S. D. Rege) joined Lensel. From 2009 onwards, Lensel has made a major push into supplying quality optics to overseas customers. From almost no exports 6 years ago, the company now earns over half of its Income from overseas customers.
4 MAJOR CUSTOMERS Customer name Product Country Yukon Advanced Optics Plastic Aspheric lenses, glass doublets Belarus Entrupy Glass Multi-lens imaging system USA Comar Optics Glass lenses, plastic lenses UK Qioptiq Glass Lenses UK Vrije Universitait Plastic Table Top Telescope Lenses Belgium Medmont Glass Lenses Australia UltraLight Optics Glass Lenses, plastic lenses USA VALS Tech Glass Lenses, Plastic domes Canada Bhabha Atomic Research Center (BARC) Manatec San Mina/ Medtronics λ/10 Test flats, dye-cells, Fused Silica Windows Glass Lens Imaging System for wheel alignment Otoscope containing plastic aspheric lenses India India India/ USA
5 GLASS OPTICS MANUFACTURING LINE
6 GLASS OPTICS We have both the High Speed Diamond Pellet grinding - Polyurethane Pad Polishing Line as well as the traditional Lapping machines with Emery powder and Pitch Polishers. Our High Speed Optical Center based grinding and polishing line was installed by the Korean Kwangjin in the year We have 11 Korean Machines covering every step from Curve Generation to final Edging and Centering of the Lens. We make glass singlets, doublets and triplets for defence, medical and consumer industries. We make our own Testplates and Tools. We accept orders right from prototype quantities (5-10 pieces) to bulk supply (5000 to 10,000 pieces). Our glass optics is coated in a Satisloh SP-100 Sputter Coating Chamber, which is known to provide the hardest and most durable glass lens coatings in the industry. We have a fully equipped Test facility including a Fujinon Spherical Surface Interferometer, Filmetrics Fiber Optics Spectrophotometer, Focometer with rotation stage, Spherometers etc.
7 GLASS SHOP MACHINES LENSEL OPTICS PVT. LTD Curve Generation Machine Bell Centering and Edging Machine
8 GLASS SHOP MACHINES LENSEL OPTICS PVT. LTD 2 Spindle High Speed Grinding Machine 4 Spindle High Speed Polishing Machine
9 TOLERANCES AND CAPABILITIES IN GLASS OPTICS Material Size Optical Surfaces Specifications Achieved All glasses from SCHOTT and CDGM Catalog, Fused Silica, Pyrex, Float Glass, Quartz etc. Dia 5 mm to 300 mm Spherical Specification Commercial High Precision Surface Less than 0.5 λ Less than λ/10 Irregularity Radius of +/-0.5% +/-0.1% Curvature Center Thickness +/ mm +/-0.03 mm Centration Error 3 arc minutes 1 arc minute Diameter +0.00, mm +0.00, mm Focal Length +/-1 % +/- 0.5% Scratch/ Dig 40/20 20/10
10 LENSES MADE IN GLASS SHOP SINGLETS LENSES DOUBLETS LENSES We make all types of singlets including Plano-vex, Plano-Cave, Bi-vex, Bicave and Menicus Lenses. Doublet and Triplets are made using Norland Optical Adhesive (NOA 61) We use an optical centering device that allows us to achieve centration errors below 1 arc minute.
11 LENSES MADE IN GLASS SHOP NIGHT VISION OPTICS OPTICAL FLATS AND WINDOWS We supply the lenses used for Night Vision binoculars to defense suppliers in India. These systems have been used by Indian defense and paramilitary forces. These lenses, made to the highest precision levels, contain a BBAR coating that conforms to MIL spec 48497A and has an average transmission above 99% over the 550 to 870 nm range needed for these low light conditions. We can make very high precision optical flats and windows with surface accuracies of λ/10 and parallelism within 3 arc seconds. We routinely supply windows in Quartz, Fused Silica, N-BK7, or any other optical glass to various Indian Government Organizations.
12 INJECTION MOLDED PLASTIC OPTICS LINE
13 INJECTION MOLDED OPTICS We have 4 Injection Molding Machines. 3 of them are used for optical lens production while the fourth is used for molding casings and associated non-optical parts. Our 4 Molding Machines include a 150 Ton L&T Demag, 150 Ton and 100 Ton Toshiba Machines and 130 Ton Windsor Machine. Our optical molding is done within a Class 100,000 Clean Room facility with controlled Temperature and Humidity. Material handling, Drying and Mold Temperature Control is also done automatically on-line. We mold spherical lenses, aspheric lenses, filters, insert molded optics etc. for applications ranging from collimators to complex multielement imaging systems. We assemble molds in-house. Our mold bases are procured locally while our aspheric cavity inserts are imported from an internationally renowned SPDT machining firm. Spherical cavity inserts are made by our Glass Optics Manufacturing Line. We have supplied Plastic Optics to customers in the USA, Canada, Belgium, UK, Belarus, Columbia, Egypt etc.
14 TOLERANCES AND CAPABILITIES OF INJECTION MOLDING LINE Material Diameter Optical Surface Shapes PMMA (Acrylic), Polycarbonate, Zeonex (COC) 4mm to 130 mm. Max shot weight of 130 grams. Spherical, Conic, Aspheric Surfaces (Even and Odd Aspheres with higher order coefficients) Optical surface along with integrally molded features like mounting frame, pegs, notches, spacers etc. Precision Diameter tolerance : +0.00/ mm; Thickness tolerance : +/ mm; Centering tolerance: 3 arc min; Scratch/Dig : 60/40; Focal length tolerance : ± 0.5%;
15 PLASTIC OPTICS SINGLETS, DOUBLETS, ASPHERIC LENSES DOUBLE ASPHERIC IMAGING LENSES We can make any type of lens in PMMA, Polycarbonate or Zeonex with spherical, conic or aspheric surfaces. We also make plastic doublets consisting of PMMA and PC lenses bonded together. We developed these aspheric lenses with integrally molded spacers for a customer in Belarus. Both surfaces of the lenses have deep aspheric surfaces with non-zero sixth and eighth order coefficients. These lenses are used for imaging applications and require very high precision surface profiles.
16 PLASTIC OPTICS ASSEMBIES GALILEAN TELESCOPE WITH LIGHT OTOSCOPE This is a fully plastic optical system consisting of a BBAR coated plastic achromatic doublet(pmma and PC), coated plastic negative biconcave lens, plastic casing, LED housing, LED housing attachment and hinge assembly. The ocular, released in 2009, has already sold over 25,000 units. We have developed complete imaging systems consisting of aspheric plastic lenses for use in the medical field. A medical devices company recently developed an Otoscope with us using multiple aspheric lenses. We manufacture the lenses, coat them, assemble them and do the complete product testing for customer.
17 LENSES MADE IN INJECTION MOLDING SHOP INSERT MOLDED OPTICS FILTERS AND ATTENUATORS We have experience with insert molded optics where metal components are molded into the optical component to allow for easy installation of the optics in the system. The picture above shows a camera attachment with an integrally molded stud which we sell to a UK based customer. We have extensive experience in using additives in the base PMMA and Polycarbonate to create custom filters and attenuators with specified spectral transmission profiles for our customers. We have developed a Blue Day Light Filter for a leading microscope manufacturer in India. We have also developed attenuating plastic lenses.
18 COATING FACILITY SATISLOH SP-100 SPUTTER COATING SYSTEM 24 INCH IBP BOX COATER WITH EB GUN AND HHV DIGITAL THICKNESS MONITOR
19 COATING FACILITIES We have purchased the SP-100 Sputter Coating Chamber sold by Satisloh GmbH in August, We also have a 24 inch Box Coating System of Indian make (IBP System with EB Gun and HHV Digital Thickness Monitor) purchased in The Sputter Coating technology allows for extremely hard and durable coatings. The hardness and scratch resistance of the coatings made on the SP-100 is far superior to the standard MIL requirements of MIL 675C and MIL 48497A for severe abrasion. We have developed a wide range of coatings on the new Satisloh machine. These include the standard BBAR coating in the visible and near IR range as well as others such as the Ultrawide BBAR coating (covering 400 to 940 nm), Dual Wavelength coatings, Band-pass coatings, etc. We coat both glass and plastic lenses. We have a reflectance based Fiber Spectrophotometer from Filmetrics (purchased in Sept, 2015) as well as a transmission based regular Spectrophotometer from Thermo-Fisher in order to test our coatings.
20 COATINGS OFFERED BY LENSEL Standard BBAR Coating: Done on SP-100. Ravg<0.5% for 400 to 700 nm. Ravg<0.4% for 625 to 675 nm. Meets both MIL specs 675C and 48497A for severe abrasion. This coating can also be shifted to cover the NIR range from 550 nm to 870 nm Ultra-wide BBAR Coating: Done on SP-100. Ravg<0.8% for 400 to 940 nm. Meets all MIL specs. Very Low Reflection BBAR: For small wavelength ranges like 500 to 600nm, we can offer a coating with Ravg<0.2% over this range. Very Hard BBAR Coating: This is a very hard BBAR coating done on the SP-100. It is usually used on watch-glasses and other optics expected to undergo rough, out-door use. It has 1000 Vickers hardness and is claimed by Satisloh as the hardest AR coating available today. Ravg<1% for 400 to 700 nm. Single Layer MgF2 coating done on Box Coater Machine. We are able to offer very economical coatings on account of the large size of our box coater.
21 COATINGS OFFERED BY LENSEL BBAR Coating on Plastic Optics: This is the standard visible multi-layer coating done on plastic optics. It has an anti-scratch layer to improve the scratch resistance of the lenses. On customer request, we can also get the lenses dip coated (hard coated) from our associate followed by the AR coating. This gives maximum scratch resistance to plastic optics. This is done on the Box coater and is very cost effective. Dual Wavelength Coatings: These coatings done on the SP-100 are very popular in the Defense and Night Vision fields. It usually involves good performance over the visible or NIR range along with a peak transmission at some specific wavelength outside the range. Typical spec: Ravg<0.5% for 400 to 700 and R<0.5% at 1550 nm. Filters High pass, Band pass and notch. The SP-100 is capable of doing highly accurate coatings with layer stacks, which allows us to develop various types of filter coatings based on customer requirements.
22 STANDARD BBAR COATING Ravg < 0.5% for 400 to 700 nm.
23 ULTRAWIDE BBAR COATING Ravg < 0.8% for the extended range of 400 to 940 nm
24 TEST AND INSPECTION EQUIPMENT FUJINON INTERFEROMETER FILMETRICS SPECTROPHOTOMETER The Interferometer is used mainly for measuring the surface irregularity of spherical surfaces. The interferometer also comes with a digital scale that can be used for measuring radius of curvature. The interferometer can measure radii of curvature from +150 mm to -250 mm. We have two spectrophotometers. The Filmetrics instrument, shown above, is a fiber optic based spectrophotometer that can measure the reflectance of a sample. It can be used even on curved surfaces. Its range is from 380 nm to 1700 nm. We also have a Thermo Fisher transmission based Spectrophotometer that can measure transmission of flat samples from 200 nm to 1100 nm
25 TEST AND INSPECTION EQUIPMENT FOCOMETER MINOR MEASURING INSTRUMENTS We have made our own certified Focometer complete with collimator, measuring microscope, digital scale and rotation stage. The Focometer can measure Back Focal Distance up to 200 mm. The rotation stage allows us to rotate the lens while the measuring microscope allows us to measure the resulting deviation and thus compute the centration error. We measure the center thickness of the lens using a 1 micron LC Mitutoyo Digital Gauge mounted on a stand. We measure the diameter of the lens using a go-nogo gauge or Vernier Callipers. For Radii of Curvature outside the range of our interferometer, we use ball cup spherometers of various sizes
26 TEST AND INSPECTION EQUIPMENT LENS AESTHETICS INSPECTION TABLE VIDEO INSPECTION AND MEASUREMENT SYSTEM We have developed special tables that allow for quick and detailed inspection of the lenses for aesthetic defects like scratches, digs, pits etc. The table has a 4X Magnifier to allow for magnified view of the lens. The lens is viewed under a bright collimated halogen light beam that scatters off any defect (like a scratch) to make it immediately visible against a black background. For First Article Report for newly molded plastic injection molded components, we use a Video Inspection and Measurement systems to measure the linear dimensions and other features.
27 CONTRACT MANUFACTURING Since the last 2 years, Lensel has been offering complete end-to-end product manufacturing and testing services to our customers. Lensel is uniquely positioned in having the capability to make Glass Optics, Plastic Optics, Coating, Cementing and Assembly at a single site thus allowing us to offer a wide variety of support to our customers. We are also located in one of the largest industrial zones in the country next to the Tata Motors Car and Truck Manufacturing Plant. This ecosystem allows us to access quality suppliers locally for any specific process such as precision machining, wire cutting, painting, powder coating, anodizing etc. We are thus able to make complete products for our customers as per their designs. We assist them right from design/ prototype stage up to full scale production. In this area, we have worked with various start-ups and established product development companies (such as Medtronics, USA) on products such as a Plastic Galilean Ocular Loupes with Hinge and LED Light, Plastic Otoscope, Glass Lens Layout for Wheel Alignment, Glass Lens layout for cloth texture determination, Underwater Camera equipment etc.
28 CONTRACT MANUFACTURING PRODUCTS 4 Lens Assembly for Wheel Alignment Galilean Loupe with Plastic Lenses including Hinge and LED light 6 Lens Micro-assembly for detecting material texture Otoscope with 3 plastic aspheric lens assembly for imaging inner-ear.
29 SENIOR MANAGEMENT AT LENSEL Mr. S. D. REGE (Founder and Director) Mr. S. M. REGE (Director) Mr. S. D. Rege completed his B.Tech in Chemical Engineering from the IIT-Bombay in 1970, his MS from Columbia and MBA from the University of Chicago. He worked in the US for many years and returned to found Lensel in He is the majority share holder of Lensel and is still involved with the company as a Director in a part-time capacity. Mr. S. M. Rege completed his B.Tech in Mechanical Engineering from IIT-Kanpur in He joined Lensel in 1981 and is the minority share holder in the company. He is involved full-time as a Director in the. He overseas the Finance, Accounts and Purchase departments.
30 SENIOR MANAGEMENT AT LENSEL Mr. Sid REGE (CEO) Mr. M. B. DOSHI (GM, Marketing) Mr. Sid Rege, son of Mr. S. D. Rege, completed his BS and MS in Optical Engineering from the Optical Sciences Center at the University of Arizona in He holds 5 US patents for camera systems and IR safety system designs. He has been with Lensel since He is currently the acting CEO of the and also overseas the Production and QC Departments. Mr. Doshi joined Lensel in 1984 and is one of the founding members. He is currently in charge of Marketing and personally manages the accounts of all our key overseas customers.
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