From optical design to shaping, laser polishing, and laser form correction to adjustment and packaging, the Fraunhofer ILT offers a fully integrated, laser-based manufacturing process unique in the world. This addresses manufacturers and users from fields such as medical technology, laser optics, or microelectronics.
[Laser-based manufactured monolithic double-sided microlens array for the homogenization of laser radiation. The fully laser-based process chain enables efficient production of complex optical surfaces.]
From Tradition to Innovation
The name Fraunhofer has stood for advances in optics for over two hundred years. The physicist and optician Joseph von Fraunhofer developed new methods for the production and characterization of precise glass optics in the early 19th century, laying important foundations for modern optical manufacturing.
Today, researchers at Fraunhofer ILT continue this tradition while simultaneously driving a disruptive technological change: laser-based processes are set to replace conventional manufacturing steps that still require regular manual interventions, enabling fully digital, highly automatable process chains. The result: even complex geometries such as aspheres, freeform optics, or microstructured surfaces can be efficiently produced and corrected – whether microlens arrays in the submillimeter range or complex aspheres in the centimeter scale.
[Even the most demanding geometries can be efficiently produced without additional tooling effort. Here: Freeform lens for logo projection, after laser ablation (left), laser polished (middle), and anti-reflective (right.)]
Manufacturing complex optics without additional effort
At Fraunhofer ILT, the individual laser-based processing steps seamlessly interlock. Starting with laser-based shaping, glass blanks can be precisely preformed. In subsequent steps, laser polishing and, if necessary, laser form correction ensure that surfaces are smoothed and shape deviations in the nanometer range are compensated. The manufacturing technology is complemented by manufacturing-friendly optical design and methods for active adjustment and packaging of optical components. This creates a continuous, digitally controllable process chain that allows for the efficient production and integration of both individual optics and complete optical assemblies.
"The laser is indifferent to the complexity of the optical geometry," explains Dr. Edgar Willenborg, group leader for polishing at Fraunhofer ILT, highlighting the key advantage. "Aspheres, freeform surfaces, or special geometries can be realized with the same tool without significant additional effort. Only the measurement technology becomes more complex." Willenborg refers to this principle as "Complexity for Free." In classical manufacturing, an asphere can cost five times more than a comparable sphere – a difference that is eliminated with laser-based methods.
Martin Kratz, group leader for in-volume structuring & lithography at Fraunhofer ILT, explains another technical advantage: "By working the laser through the glass, the front side, back side, and edge cylinder of an optic can be produced in a single setup with the highest precision of the optical axes relative to each other. The spectrum ranges from microlens arrays with individual lenses starting at 500 micrometers to macro optics currently up to 80 millimeters in diameter." In the future, the research groups aim to scale their manufacturing processes to larger diameters.
[Aspherical gullwing lens with a diameter of 40 mm after laser-based shaping and before polishing.]
Laser-based optical manufacturing on the way to industry
Fraunhofer ILT believes the time has come to transfer these technologies into industrial practice. "After many years of fundamental process development, we are on the threshold of industrial implementation," says Edgar Willenborg. "The growing cooperation with machine manufacturers shows: the industry is ready to take this step." Thus, Fraunhofer ILT is specifically targeting companies that want to integrate laser-based optical manufacturing into their own production.
Laser-based optical manufacturing opens up new possibilities for applications where complex geometries and flexible manufacturing are required. This includes, for example, optical systems for medical technology as well as laser optics for industrial applications and optical components for microelectronics. In future fields such as quantum technology, EUV lithography, or fusion research, the demand for high-precision special optics is also increasing.
"Many modern optical systems today require customized geometries that can only be produced with great effort using classical methods," explains Martin Kratz. "Laser-based processes enable such optics to be produced flexibly and economically – especially when complex geometries are needed."
Technology transfer from research to production
"The service offering of Fraunhofer ILT covers the entire range from the initial concept to the support of industrial implementation. Often, a feasibility study is the first step, in which it is jointly examined with the customer whether and how the laser-based processes can be adapted to their specific optical designs and requirements," adds Dr. Christian Vedder, head of the department "Surface Technology and Ablation." Building on this, Fraunhofer ILT manufactures prototypes and small series, as demonstrators and for process validation. In the next step, the institute supports its customers and project partners in the industrial introduction of the new manufacturing processes into their own production. Where no suitable machines are available on the market, Fraunhofer ILT develops and builds them on request.
Currently, around 12 scientists are working on laser-based optical manufacturing at Fraunhofer ILT. Two research focuses are currently in the spotlight: on the one hand, the integration of sensor systems into the manufacturing processes to further increase the shape accuracy of the produced optics. On the other hand, the optimization of the process chain with the aim of increasing the laser-induced damage threshold of optical surfaces, a crucial quality parameter, especially for high-performance laser optics.
At Optatec from May 5-7, 2026, in Frankfurt am Main, Fraunhofer ILT will present selected demonstrators along this process chain at Stand 219 in Hall 3. Researchers from the institute will be available during the fair for discussions about specific applications, process development, and cooperation opportunities. In addition, Fraunhofer ILT will participate on May 6 with a technical lecture and a subsequent panel discussion in a program by SPIE optics.org.
Fraunhofer ILT at Optatec 2026 in Hall 3 at Stand 219
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