Zemax Modeling
& Optical Simulation
Expert Zemax OpticStudio consulting for precision optical design — from sequential ray tracing and tolerance analysis to non-sequential illumination modeling with custom DLLs. We turn your optical requirements into validated, production-ready designs.
- Sequential & non-sequential
- Custom DLLs & algorithms
- 20+ years experience
Sequential & Non-Sequential
Full ray tracing in both Zemax modes for imaging and illumination
Custom DLLs
Proprietary algorithms and DLLs for advanced surface types and optimization
Tolerance Analysis
Monte Carlo and sensitivity analysis for manufacturing feasibility
800+ Systems Designed
Proven track record across dozens of industries and applications
Comprehensive Optical Modeling & Analysis
We leverage deep Zemax expertise to deliver precise, optimized optical designs for any application.
Optical System Design
Complete lens system design from first principles — singlets through complex multi-element systems. Optimized for your wavelength range, field of view, and packaging constraints.
Tolerance Analysis
Monte Carlo simulations and sensitivity analysis to assess the impact of manufacturing tolerances on optical performance. Ensures your design is producible.
Performance Optimization
Multi-configuration optimization, merit function engineering, and global search strategies to push your optical system to peak performance.
Stray Light Analysis
Non-sequential ray tracing to identify and eliminate ghost images, scatter, and unwanted reflections that degrade image quality or system performance.
Thermal & Structural Analysis
Evaluating the effects of temperature changes and mechanical stresses on optical systems. Integrated with FEA tools for complete thermo-optic modeling.
Custom DLL Development
Proprietary Zemax DLLs for advanced surface types, custom optimization operands, and specialized modeling capabilities beyond standard Zemax features.
Zemax Modeling Across Industries
Our Zemax expertise spans imaging systems, illumination optics, and specialized applications.
Medical & Life Sciences
Endoscopes, ophthalmoscopes, confocal imaging, and fluorescence collection systems
Imaging & Projection
Camera systems, cinema projectors, VR/AR headsets, and motion capture optics
Illumination Systems
LED optics, freeform reflectors, light pipes, and automotive lighting
Defense & Aerospace
Night vision, IR systems, targeting optics, and ruggedized optical assemblies
Industrial & Metrology
Barcode readers, distance measurement, laser marking, and inspection systems
Scientific & Research
Microscope objectives, MEMS optics, CARS imaging, and custom Zemax DLLs
Zemax Modeling in Action
Real projects where our Zemax expertise delivered validated, production-ready optical designs.
VIS-NIR Dual-Band Imaging Lens
Complete Zemax design of a 35 mm f/1.65, 7-element lens for a fluorescence-guided surgical system. Sequential optimization with tolerance analysis through prototyping.
High-NA Fluorescence Collection Lens
Zemax modeling and optimization of a high-NA collection lens for flow cytometry. Performance validated through prototyping and production transfer.
Freeform Grow Light Reflector
Non-sequential Zemax design of a freeform reflector and Fresnel lens for uniform high-PPFD vertical farming illumination using custom Bezier surface DLLs.
Why Choose Our Zemax Consulting?
Experienced Team
Our engineers have 20+ years working with Zemax OpticStudio daily. We've modeled over 2,000 optical systems across sequential and non-sequential modes.
Tailored Solutions
Every project gets a customized approach — from quick feasibility studies to full design-through-production modeling with tolerance analysis and stray light evaluation.
Custom DLL Expertise
We develop proprietary Zemax DLLs for Bezier freeform surfaces, custom optimization operands, and advanced modeling capabilities that standard Zemax can't achieve.
Expertise in Zemax FAQs
What Zemax consulting services does Optics for Hire offer?
We offer comprehensive Zemax OpticStudio consulting including sequential and non-sequential ray tracing, optical system design from first principles, tolerance analysis (Monte Carlo and sensitivity), stray light analysis, thermal and structural analysis, performance optimization, and custom DLL development. Our Zemax engineers have 20+ years of daily experience modeling over 2,000 optical systems.
What is the difference between sequential and non-sequential Zemax modeling?
Sequential Zemax modeling traces rays through optical surfaces in a predefined order — ideal for imaging lens design, camera systems, and telescope optics. Non-sequential Zemax modeling allows rays to interact with any surface in any order — essential for illumination design, stray light analysis, light pipe modeling, and LED optic optimization. Our Zemax consultants are expert in both modes and select the right approach for your application.
Can you develop custom Zemax DLLs for my project?
Yes. Custom Zemax DLL development is one of our specialties. We create proprietary DLLs for advanced surface types (including Bezier freeform surfaces), custom optimization operands, and specialized modeling capabilities that go beyond standard Zemax OpticStudio features. Our custom DLLs enable optimization and analysis that are not possible with built-in Zemax functionality.
What size companies do you work with?
Our Zemax consulting services support companies of all sizes — from university research groups needing optical simulation support to large defense contractors requiring complex multi-configuration Zemax models. Whether you need a quick feasibility study, a complete Zemax optical design with tolerance analysis, or ongoing optical engineering support, we tailor our Zemax consulting to your project scope.
Can you help me make a prototype?
Yes. Our Zemax consulting goes beyond simulation. Once your optical design is optimized and validated in Zemax OpticStudio, we manage prototype fabrication through trusted manufacturing partners and verify performance against the Zemax model predictions. Our tolerance analysis ensures your design is producible before you invest in prototyping.
Can you help with volume production?
Yes. Our Zemax optical design process is specifically geared toward production-ready results. We perform thorough tolerance analysis and Monte Carlo simulations to ensure your optical system can be manufactured consistently at volume. When your design is validated, we provide full production documentation and support the transition to volume manufacturing. For clients with internal manufacturing and existing suppliers that means we support their resources, for clients who need OFH to manage production it means we use our supply chain
What types of optical systems do you model in Zemax?
We model a wide range of optical systems in Zemax OpticStudio including medical optics (endoscopes, confocal imaging, flow cytometry), camera and projection systems, VR/AR headset optics, illumination systems (LED optics, freeform reflectors, grow lights), defense optics (night vision, IR systems, targeting), industrial metrology (barcode readers, laser systems), and scientific instruments (microscope objectives, MEMS optics, CARS imaging).
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Location
Boston, MA Area
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