Mould Processing

Optical design by development of our own software

Optical design is the most important process determining the characteristics of optical parts, such as lenses and mirrors. As customers’ requirements diversify, the optical design software currently on the market is unable to cover all of them. As a result, we have developed our own software that enables us to make a suitable optical design based on a customer’s various requirements. Our own development software also enables us flexibility in reforming a program for a customer’s new request.
Our optical design program itself is perpetually developing along with the changing needs and requests of our customers.

Click on small pictures to enlarge


High accuracy mirror surface processing

Our special technique is also applied here.
It is generally necessary that mirror polishing be applied to the surface of an optical product, and that accuracy of this surface hugely influences the characteristic of an optical product. CAD and CAM software currently on the market are unable to fully satisfy a customer’s requirements on this step as well as Optical Design.
Not only a processing program linked to optical design data but also our unique precision processing technique enables compatibility with mirror processing and surface accuracy.

Our unique multi-segments optics’ mould (for Infrared sensors to detect human motion)

Our moulds of multi-segments Fresnel lens are constituted by a combination of blocks Fresnel groove surfaces processed on every segment. Every segment is created as an ideal mould of an optical part in injected products, which is completely different from copy-mould type Fresnel lenses. This method is also applied to a multi-segments type mirrors.

Direct Cutting

Experienced plastic injection

The tuning condition of a plastic injection is largely influential over product accomplishment. Here are just typical examples of tuning parameters;

• Kinds and shrinking ratio of a plastic material
• Melting temperature of a plastic material
• Injecting pressure of melting material into mould
• Mould temperature and its distribution
• Cooling-off time

These are just a few samples. Product accuracy is immediately affected, even if only one tuning condition is not optimized. There are of course, logical decision parameters, however, are influenced by external conditions, such as environmental temperature. Our knowledge built upon experiences of trial and error has been essential in deciding a moulding condition. We, at JAPAPLALENS, in terms of a theory and experience have perfected production through our technicians’ expertise in moulding conditions for over 20 years, since we were established.

Direct Cutting

Manufactures a variety of types but small in quantity

When above technique of Mould Processing is applied to a lens material like acrylic, it becomes possible to cut the lenses directly out from a material block..
Although unsuitable for big quantity production, It is possible to leave out the process of Mould Design and Processing, Sample Injection, and “Adjustment of a injecting condition” in Business Flow. This enables us to both shorten a delivery lead time and produce a super high accuracy lens uninfluenced by moulding conditions.
Please ask us this when you intend to have check-up sample or “a variety types but small in quantity” product.


Various materials are available as follows;

• Acrylic (Transparent and filter grade)
• Polycarbonate (Transparent and filter grade)
• Polyethylene (For infrared sensor)
• ABS (For mirror base material)
• Super Engineering Plastics, etc….

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