GoPhotonics interviewed Dr. Stefan Hambuecker, the Managing Director of INGENERIC. After earning his degree in mechanical engineering from RWTH Aachen University in 1996, Stefan Hambuecker started his career as a Research Assistant at the Fraunhofer Institute for Production Technology in Aachen, where he also completed his doctorate in 2001. Shortly afterwards, INGENERIC was established as a spin-off from Fraunhofer IPT, with Stefan Hambuecker taking on the responsibilities of Managing Partner. His extensive technical expertise and many years of industry experience are key drivers of INGENERIC's innovations in optical solutions.
Q. Could you provide an overview of INGENERIC GmbH? When was the company established, and what were its initial goals?
Dr. Stefan Hambuecker: INGENERIC was founded in 2001 as a spin-off of the Fraunhofer Institute for Production Technology (IPT) at the technology and research hub in Aachen. Back then, the company was established as supplier of micro-optics for high power diode lasers.
Today, our headquarter, including an integrated production facility, is located in Baesweiler, nearby the high-tech region of Aachen. This new facility, opened in 2019, meets the specific requirements for efficient production with its state-of-the-art infrastructure. Covering an area of 3,200 square meters, over 100 employees work diligently to ensure our international business partners and customers always receive their products in the best quality and on time.
We have been recognizing clear trends in photonic applications for years: Optical surfaces are becoming increasingly complex, mobile applications require small systems that save space and weight. Miniaturization is an important trend. In addition, there is an increasing demand for highest quality in large quantities and at the lowest possible cost.
At INGENERIC we have recognized these market expectations many years ago and adapted our manufacturing concept. Today, INGENERIC is the leading European company for molded precision optics made of glass.
Q. Can you tell us about INGENERIC’s product portfolio?
Dr. Stefan Hambuecker: With extensive experience, we manufacture refractive micro-optics, beam transformation optics, lens arrays, and aspheres with exceptional properties. These can be provided as standard optics or tailored to customer-specific requirements.
Our product portfolio includes:
We use high-quality glass materials from various suppliers and meet stringent precision specifications in serial production. Our continuously optimized engineering designs ensure maximum brightness and reliability.
Q. Could you explain the differences between fast-axis and slow-axis collimation optics and highlight their specific applications?
Dr. Stefan Hambuecker: Fast-axis and slow-axis collimation optics are used to manage the divergent beams produced by laser diodes, which typically have different divergence rates along two perpendicular axes.
Fast-axis collimation (FAC) optics are designed to collimate the beam along the axis with the highest divergence, known as the fast axis. These optics use acylindrical lenses with high numerical apertures to collect and collimate the highly divergent light. They are commonly used in high-power laser diodes, such as those in materials processing (e.g., cutting and welding), medical applications, and optical communication systems.
On the other hand, slow-axis collimation (SAC) optics are designed to collimate the beam along the axis with lower divergence, known as the slow axis. These optics typically use cylindrical lenses or arrays to manage the less divergent light. SACs are often used in conjunction with FACs to fully collimate the output of laser diodes, ensuring a more symmetrical beam profile. This is crucial in applications requiring precise beam shaping, such as in laser projectors and certain types of imaging systems.
The key difference between FACs and SACs lies in their handling of divergence: FACs handle the fast axis (high divergence), while SACs handle the slow axis (low divergence). FACs are essential for reducing the beam’s height and making it more manageable, whereas SACs help in achieving a more rounded beam profile when combined with FACs.
By using both types of collimation optics, laser systems can achieve high-quality, symmetrical beams suitable for a wide range of applications.
Q. INGENERIC’s beam transformation optics are highly regarded in the industry. Could you elaborate on the technology behind these optics and their primary applications?
Dr. Stefan Hambuecker: Beam transformation optics are valued for their precision and efficiency across various industries. They are primarily used in material processing, such as laser cutting, welding, and engraving. In medical applications, they provide the precision needed for procedures like laser eye surgery. In optical communication, they improve beam quality for reliable data transmission. Moreover, they are also employed in scientific research.
INGENERIC’s beam transformation optics are indeed highly regarded for their ability to manipulate and shape laser beams with high precision. These optics are designed to homogenize the beam parameter product (BPP) of the fast and slow axis which is crucial for example for coupling laser diode bars into fibers as well as dense wavelength beam combining.
Our beamPROP achieves the highest beam quality through the following four main features:
- Complete utilization of the aperture by minimized transition zone
- Minimum aberrations achieved by highest level of precision and uniformity of single lenslets
- An exact rotation of the emitter is achieved through the defined center thickness accuracy
- Minimum pointing errors due to an exact position of front and back surfaces.
Beside that example for a beam transformation optic other lenses or designs can be realized by INGENERIC’s manufacturing technology.
Q. The microlens arrays developed by INGENERIC are part of NASA's PACE project for ocean colour monitoring. What design features make these arrays suitable for such high-precision applications, and what was the experience of collaborating with NASA on this project like?
Dr. Stefan Hambuecker: In the development of the OCI (Ocean Color Instrument) for NASA's PACE project, microlens arrays from INGENERIC, manufactured using the so-called precision molding process, proved to be far superior to etched arrays: They exceeded NASA's original requirements and will significantly enhance the efficiency of coupling light from the ocean surface into the optical system's fiber optics of the satellite.
Transition zones from the INGENERIC MLA were almost an order of magnitude smaller than the MLAs produced by lithographic methods. Furthermore, pitch analysis of the INGENERIC MLA showed an exceptional accuracy with pitch errors <1 µm. Furthermore, using the qualitative laboratory bench-top imaging test, NASA observed a considerable decrease in the ‘light leakage’ areas from the MLA interface, which again shows a qualitative improvement in the performance of the MLAs.
NASA attributed the superior performance of INGENERIC’s MLAs to the manufacturing process: Precision molding of aspherical microlenses that enables the design specifications for the shape of the lenses to be met with the highest precision. In this way, the lenses achieve optimum image quality. This is especially true for the edges of neighboring microlenses when coupling into glass fibers: If they are not manufactured precisely, light is scattered into the transition zones between the fibers and cannot be used for coupling.
We are proud that our company has proven itself as a supplier to NASA and has impressed with the quality of our products. The use of our microlens arrays in the PACE mission not only highlights our company's technological excellence but also our shared commitment to the exploration and preservation of our planet. It is an honor to be part of a project that deepens the understanding of the complex interactions between the ocean and atmosphere, ultimately contributing to a more sustainable future.
Q. As a company certified under DIN ISO 9001:2015, how does INGENERIC ensure high-quality standards across its product line? Are there any specific quality control processes that you consider crucial for precision optics?
Dr. Stefan Hambuecker: For INGENERIC, quality is our top priority. Therefore, the DIN ISO 9001:2015 certification reinforces our ongoing commitment to the highest quality standards, efficiency, and customer satisfaction.
We ensure high-quality standards across our product line through a comprehensive quality management system that covers all aspects of our operations, from raw material procurement to the final inspection of finished products.
We implement stringent quality control processes that are crucial for precision optics. This begins with supplier quality management, where we carefully select and regularly audit our suppliers to ensure they meet our high standards for raw materials and blanks. Throughout the manufacturing process, we use advanced measurement technologies, to monitor and maintain precision. Before any product is shipped, it undergoes a thorough final inspection to verify that it meets all specifications and quality standards. Additionally, we continuously optimize our processes based on feedback and new technological advancements to maintain and enhance our quality standards.
Q. INGENERIC uses precision glass molding for manufacturing optical components. What are the key advantages of this method compared to other production techniques?
Dr. Stefan Hambuecker: We use precision molding, a forming technology that transforms simply shaped glass blanks into complex optics using a high-temperature process. The glass blanks are fed into the molding machine at room temperature, heated together with the tool systems and finally cooled in a controlled manner after forming.
The technology has enormous advantages and USPs over alternative processes like grinding/polishing or etching:
- Complexity of optical shapes (aspheres, arrays, torics, freeforms etc.)
- High form accuracies <1 µm PV
- Surface quality < 2-3 nm Rq
- High reproducibility
- Scalability for prototyping and large volume production
- Different high-index glass types usable
- Larger CA/pitch ratios
- Small transition zones
Q. With SPIE Photonics West 2025 approaching, could you share the key insights or partnerships that emerged from your recent experiences, and how events like these support INGENERIC's position at the forefront of the optics and photonics industry?
Dr. Stefan Hambuecker: SPIE Photonics West is a key event for the optics and photonics industry, providing a platform for networking, innovation, and collaboration. From our extensive experience, we’ve gained valuable insights into cutting-edge research in areas like biomedical optics, AR/VR/MR hardware and quantum technologies. These insights help us to stay updated and integrate the latest advancements into our products.
Networking opportunities at Photonics West allow us to connect with industry leaders, potential clients, and collaborators, fostering relationships that can lead to new business opportunities. Showcasing our latest innovations at the event helps reinforce our position as a leader in the industry and provides direct feedback from peers and potential customers.
By participating in SPIE Photonics West and similar events, we enhance our knowledge, strengthen our network, and maintain our market presence, ensuring we remain at the forefront of the industry.
Q. What steps has INGENERIC taken to reduce energy consumption in production, and how are these measures integrated into your business practices?
Dr. Stefan Hambuecker: At INGENERIC, sustainability is a core part of our philosophy, emphasizing economic and ecological responsibility. Our strategy focuses on reducing energy consumption in manufacturing and increasing the use of renewable energies. By adopting advanced technologies and production processes, we aim to conserve resources and minimize our ecological footprint.
In the past two years, we’ve saved 8.8% electricity (46 tons of CO²) and 16.9% gas (18.3 tons of CO²), totaling 64.3 tons of CO² savings. This not only benefits the environment but also provides economic advantages for our customers.
Looking ahead, we plan to continually reduce energy use and invest in environmentally friendly energy sources. We aim to cut our emissions (Scope 1+2) at our Baesweiler site by 4.2% annually until 2030, including at least 1.5% electricity and 3% gas each year.
As part of our climate strategy, we are exploring investments in heat recovery and solar systems to enhance energy efficiency and secure our energy supply. Since 2016, we’ve implemented an energy management system in line with DIN EN ISO 50001 for developing and producing micro-optics, optical systems, and laser systems. This system helps us identify further savings and move towards carbon neutrality.
Q. Does INGENERIC primarily develop standard catalog products, or do you focus on custom products based on specific customer requirements?
Dr. Stefan Hambuecker: Our mission is to provide our global customers with the best optical solutions and excellent service. Therefore, we offer both standard catalog products as well as design-in products based on specific requirements.
Regarding our customers, we see ourselves as a development partner - always with the goal of bringing about the best possible optical solution for every challenge.
We have extensive experience and expertise in a wide range of technologies, extending from ultra-precision machining and micro-structuring to ultra-precision glass molding for mass production environments.
Based on our broad technology portfolio we are capable of offering flexible solutions in many aspects. For our customers we process different materials and flexible geometries, we offer customized assembly, we manufacture beneficial prototype, small series, or mass production quantities – to mention but a few and all of this in high-precision-standard.
Q. Could you describe how INGENERIC collaborates with clients to design bespoke micro-optic solutions and discuss any challenges encountered in meeting diverse optical requirements?
Dr. Stefan Hambuecker: In the field of customer-specific optics, we act as follows: First, we design or adapt the components to our technology in collaboration with the customer. Next, we determine all necessary specifications. Following this, we convert the components into prototypes. We then evaluate and, if necessary, optimize them. Finally, we proceed with planning and ramp-up.
Our mission is to provide our global customers with the best solutions and excellent service. Therefore, continuous exchange with our customers is very important to us, because this is the only way we can ensure that we meet our customers' requirements in terms of quality and precision of our optics.
Q. Who are your main customers, and where are they predominantly located?
Dr. Stefan Hambuecker: Our customers are primarily from the laser, datacom and healthcare industries. In addition, our customers also include companies from emerging growth markets, such as Industrial Lidar and VR/AR applications. Regionally, our customers and target markets are spread across the continents of the USA, Europe and Asia.
Q. Which market segments do you target?
Dr. Stefan Hambuecker: The applications for optical components are extremely diverse. Key markets that rely on precise and high-quality optics include laser and sensor technology, the telecommunications sector, and healthcare.
Historically, INGENERIC is strong in the laser technology. This was our first market when we established the company in 2001 as supplier of micro-optics for high power diode lasers.
Besides we are excited to address other interesting markets, which have strong growth perspectives in common:
- The Healthcare Industry e.g. requires complex optics in many applications like 4K endoscopy or ophthalmic.
- In Optical Data Communication we recognize a large demand for fiber coupled optics. This is maybe the fastest growing market, as our micro lens arrays are applied in transceiver modules and cross optical switches.
- Our molded optics are applied in sensor technologies like distance sensors, LIDAR sensors, confocal sensors.
- We have applications in VR/AR/MR Reality, head up displays or smart glasses.
- Last example is the Satellite Technology, where INGENERIC Micro Lens Arrays are applied for the spectral analysis of emitting light from the earth surface.
Q. What can you share about INGENERIC's product roadmap for the next three years, and what key developments can we expect from the company during that period?
Dr. Stefan Hambuecker: Over the past few years, we have been recognizing clear trends in photonic applications: Optical surfaces are becoming increasingly complex, mobile applications require small systems that save space and weight. Miniaturization is an important trend. In addition, there is an increasing demand for highest quality in large quantities and at the lowest possible cost.
In terms of our process chain, we are very well positioned to meet the customer’s need for prototyping, small-batch production and automated series-production. Furthermore, we are committed to pushing the boundaries of what is possible, ensuring our customers' success with not only high-function designs but also cost-effective products.
About INGENERIC
INGENERIC seamlessly blends technological leadership, innovation, and precision craftsmanship to deliver state-of-the-art micro-optics and optical systems for a wide range of industries. From high-power diode lasers and datacom applications to medical photonics, the company provides tailored solutions that meet the most demanding specifications. With its advanced facilities, expanded capacities, and dedicated workforce, INGENERIC upholds a commitment to quality, sustainability, and long-term partnerships. As a trusted partner, the company continues to push the boundaries of photonics, driving progress and excellence on a global scale.
