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Injection molding of thick optical elements

Thick optical components are couldn't be manufactured using regular injection molding process due to surface deformations as explained below:

After injection plastic is boiling inside and cooled outside

As a result, warping of optical surface happens

Special manufacturing process to prevent thick lens optical surface warping was developed and used for mass production; kept in secret

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Today we are able to inject 4 thick optical elements at once reducing the costs of production