Overview:
Our Custom High Standard Plastic Injection Mold Tooling for Vehicle Optical Lens Parts is meticulously engineered to meet the demanding optical and dimensional precision required by automotive lighting systems, including headlamps, taillights, and interior lens assemblies. Designed for clarity, surface accuracy, and stability, these molds are built using premium tool steels such as S136, NAK80, and H13 — materials renowned for their exceptional polishability, hardness uniformity, and resistance to corrosion and deformation.
With advanced CNC machining, mirror EDM, and high-speed milling processes, each mold achieves ultra-smooth surfaces (Ra ≤ 0.05 μm) suitable for optical-grade clarity and distortion-free transparency. Optimized gating, venting, and conformal cooling systems ensure uniform filling, reduced cycle times, and zero optical defects such as flow lines, weld marks, or sink marks. From concept validation to full-scale production, we provide complete DFM support, rapid sampling, and high-volume molding solutions tailored for precision automotive lens applications.
Basic Information:
| Specification | Details |
|---|---|
| Material Options | S136, NAK80, H13, P20, 738H |
| Process | High-Speed CNC Machining, Mirror EDM, Precision Polishing, Wire Cutting |
| Surface Finish | Optical-Grade Mirror Finish (Ra ≤ 0.05 μm), SPI A1 Standard |
| Mold Type | Multi-Cavity, Hot Runner, or Cold Runner |
| Lead Time | Prototype: 10–15 Days / Production: 4–6 Weeks |
| Tolerance | ±0.005 mm (critical optical dimensions) |
| Molding Material | PC, PMMA, PC+ABS (Optical Grade) |
| Mold Life | 500,000 – 1,000,000 Shots |
| Certification | ISO 9001, IATF 16949, RoHS, CE |
| Application | Automotive Lighting Lens, Interior Optical Components, Sensor Covers |
Key Advantages:
- Optical Precision: Ultra-fine mirror EDM and high-polish finishing for distortion-free transparency.
- Thermal Stability: Conformal cooling and optimized mold-flow design for consistent optical properties.
- Dimensional Accuracy: Micron-level machining and alignment for complex multi-cavity lens tools.
- Material Compatibility: Designed for high-clarity resins such as PMMA and optical-grade PC.
- Durability: Corrosion-resistant tool steel and precise heat treatment extend mold life and minimize maintenance.
- Full OEM Support: End-to-end service covering DFM, simulation, mold fabrication, and sampling.
Surface Treatment Options:
- Mirror Polishing (SPI A1–A3): Achieves optical transparency for light guide and lens components.
- Hard Chrome Plating: Enhances wear resistance and prevents surface oxidation.
- Texturing (VDI, Mold-Tech): Available for non-optical zones to improve adhesion or appearance.
- Nitriding Treatment: Improves surface hardness and longevity for high-volume production molds.
Quality Assurance:
All molds undergo rigorous precision verification using ZEISS CMM, 3D optical scanners, and interferometric surface roughness testers to ensure optical consistency and dimensional conformity. Flow, venting, and cooling simulations are performed via Moldflow analysis to guarantee defect-free molding. Each mold is validated with optical inspection (transmittance, haze, and distortion tests) before shipment.
We strictly follow ISO 9001 and IATF 16949 quality management systems, ensuring full process traceability, repeatability, and compliance with automotive optical standards (ECE, SAE, and GB).
Our Factory:
Our advanced manufacturing facility integrates over 25 high-precision CNC machining centers, mirror-finish EDM systems, and ultra-fine polishing units specifically dedicated to optical tooling. Controlled cleanroom assembly zones ensure contamination-free surface finishing. Automated polishing robots and dust-free inspection rooms maintain consistent optical quality for every lens mold we produce.
Equipped with CAM/CAE systems, real-time production monitoring, and statistical process control (SPC), we deliver molds that combine precision, reliability, and longevity—helping automotive OEMs and Tier 1 suppliers achieve flawless lens clarity, light diffusion control, and aesthetic excellence.
