Laser-based manufacturing of complex glass optics: Fraunhofer ILT at Optatec 2026

Press Release / March 24, 2026

The Fraunhofer Institute for Laser Technology ILT will present its laser-based process chain for glass optics manufacturing at Optatec, May 5–7, 2026, in Frankfurt am Main, Hall 3, Booth 219. From optical design through shaping, laser polishing, and laser shape correction to alignment and packaging, Fraunhofer ILT offers a fully integrated, laser-based manufacturing process that is unique in this form worldwide. The process chain covers shaping, laser polishing, and laser shape correction, followed by alignment and packaging. Fraunhofer ILT offers a fully integrated, laser-based manufacturing process that is unique in this form worldwide.

© Fraunhofer ILT, Aachen, Germany / Ralf Baumgarten.
A laser-fabricated monolithic double-sided microlens array for homogenizing laser radiation. The fully laser-based process chain enables the efficient fabrication of complex optical surfaces.

From Tradition to Innovation

Fraunhofer has stood for advances in optics for more than two hundred years. In the early 19th century, physicist and optician Joseph von Fraunhofer developed new methods for manufacturing and characterizing precision glass optics, laying the groundwork for modern optics manufacturing.

Today, researchers at Fraunhofer ILT are building on this tradition while driving a disruptive technological transformation: Laser-based processes are replacing conventional manufacturing steps that still require regular manual intervention, enabling fully digital, highly automatable process chains. As a result, even complex geometries such as aspherics, free-form optics, and microstructured surfaces can be manufactured and corrected efficiently – ranging from microlens arrays in the submillimeter range to complex aspherical optics at centimeter scales.

© Fraunhofer ILT, Aachen, Germany / Ralf Baumgarten.
Even the most complex geometries can be efficiently produced without the need for additional tools. Shown here: a free-form lens for logo projection, after laser ablation (left), laser-polished (center), and anti-reflective coated (right).

Producing complex optics without additional expenses

At Fraunhofer ILT, the laser-based processing steps run seamlessly in one workflow. Starting with laser-based shaping, glass blanks can be precisely preformed. In subsequent steps, laser polishing and, if necessary, laser shape correction ensure that surfaces are smoothed and shape deviations in the nanometer range are corrected. This manufacturing technology is complemented by production-oriented optical design and by processes for the active adjustment and packaging of optical components. This creates a continuous, digitally controllable process chain that enables both individual optical components and complete optical assemblies to be efficiently manufactured and integrated.

“The laser is indifferent to the complexity of the optical geometry,” explains Dr. Edgar Willenborg, group leader Polishing at Fraunhofer ILT, highlighting the decisive advantage. “Aspheric surfaces, free-form surfaces, or special geometries can be produced with the same tool without significant additional effort. Only the measurement technology becomes more complex.” Willenborg calls this principle “Complexity for Free.” In conventional manufacturing, however, an aspheric surface can easily cost five times as much as a comparable spherical surface – a difference that is eliminated with laser-based processes.

Martin Kratz, group leader In-Volume Structuring & Lithography at Fraunhofer ILT, explains another technical benefit: “By having the laser work through the glass, the front, back, and edge surfaces of an optical element can be fabricated in a single setup with the highest precision in the alignment of the optical axes relative to one another. 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 plan to scale their manufacturing processes to even larger diameters as well.

© Fraunhofer ILT, Aachen, Germany / Ralf Baumgarten.
An aspheric gullwing lens with a diameter of 40 mm, after laser-based shaping and before polishing.

Laser-based optics manufacturing on the path to industrial adoption

The Fraunhofer ILT considers the time to have 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 that the industry is ready to take this step.” With this, Fraunhofer ILT is specifically targeting companies that wish to integrate laser-based optics manufacturing into their own production processes.

Laser-based optics manufacturing opens up new possibilities for applications that require complex geometries and flexible production. These include, for example, optical systems for medical technology, as well as laser optics for industrial applications, and optical components for microelectronics. The demand for high-precision specialty optics is also growing in forward-looking fields such as quantum technology, EUV lithography, and fusion research.

“Many modern optical systems require tailored geometries that are extremely difficult to manufacture with conventional methods,” explains Kratz. “Laser-based processes enable flexible and cost-effective production of such optics – especially when complex geometries are required.”

Technology Transfer from Research to Production

“Fraunhofer ILT’s range of services covers the entire spectrum, from the initial concept to support for industrial implementation. The process often begins with a feasibility study, in which we work with the customer to determine whether and how 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 for demonstration and 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 itself upon request.

Currently, about 12 scientists work on laser-based optics production at Fraunhofer ILT. Two research areas currently stand out: first, integrating sensor systems into the production processes to further increase the dimensional accuracy of the optics; second, optimizing the process chain to raise the laser-induced damage threshold of optical surfaces – a critical quality parameter, especially for high-power laser optics.

At Optatec, taking place May 5–7, 2026, in Frankfurt am Main, Fraunhofer ILT will present selected demonstrators along this process chain at Booth 219 in Hall 3. Researchers from the institute will be available during the trade fair to discuss specific applications, process development, and opportunities for collaboration. In addition, on May 6, Fraunhofer ILT will participate in a program organized by SPIE optics.org with a technical presentation followed by a panel discussion.

People who are interested can also learn about the latest developments in laser-based optical manufacturing at the AKL – International Laser Technology Congress, which will take place in Aachen, Germany, from April 22 to 24, 2026.