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  • Product Overview
  • Technical Specifications
  • Why Lens Molds Are Difficult
  • Related Custom Services
Automotive Headlight Lens Injection Mold - PMMA PC Transparent Lamp Tooling
Automotive Headlight Lens Injection Mold - PMMA PC Transparent Lamp Tooling

Automotive Headlight Lens Injection Mold - PMMA PC Transparent Lamp Tooling

Headlight and lamp lens injection molds for transparent PMMA and PC. Large height difference cavities cut on 5-axis machines, XPM pre-hardened and 1.2344 ESR hardened tool steel, hot runner with valve gate sequencing, optical grade polish, T0 samples in 6 to 8 weeks.

Automotive Headlight Lens Injection Mold - PMMA PC Transparent Lamp Tooling

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Product Overview Technical Specifications Why Lens Molds Are Difficult Related Custom Services

Automotive Headlight Lens Injection Mold

This is a production injection mold for a transparent automotive lamp lens, molded in optical PMMA or impact modified PC. The photo shows the cavity block of a headlight lens tool: two curved lens pockets with the fine faceted optics that shape the light beam, plus the runner and ejector layout around them.

Lens tools are not built like ordinary housings. The cavity has a large height difference between the deep optical zones and the thin outer flange, the two materials flow badly, and any weld line, flow mark or residual stress shows up immediately as an optical defect. The tool therefore has to be machined, polished, tempered and vented to a much tighter standard than a structural part.

Applications

  • Headlamp outer lens and inner lens
  • Tail lamp and rear combination lamp lenses
  • Daytime running light and fog lamp lenses
  • Turn signal and position lamp covers
  • Two shot lamp housings with hard coat

Molded material

  • PMMA optical grade, high light transmission, mold temperature 80 to 100 C
  • PC impact modified, high viscosity and poor flow, mold temperature 90 to 120 C
  • Wall thickness 1.5 mm to 4.0 mm, deep optical zone against thin flange

Mold steel

  • Cavity and core: XPM pre hardened plastic mold steel, about 38 to 42 HRC, high polishability for optical surfaces
  • High wear and high load inserts: 1.2344 ESR (H13 ESR), hardened and tempered to 48 to 52 HRC, vacuum quenching
  • Sliders, lifters and wear plates: 1.2344 ESR or S136 hardened, nitrided where the melt is aggressive

Machining and finishing

  • All curved cavity surfaces cut on 5 axis high speed machining centers, no hand blending on the optical zone
  • Surface profile tolerance plus minus 0.02 mm, polishing allowance controlled to keep the optical geometry
  • Optical polish to SPI A1 / A0, no visible tool marks under a light beam
  • Blue light 3D scanning and color map report on the cavity before assembly

Runner and temperature control

  • Hot runner with valve gate, 2 to 8 drops sequenced to move the weld line into a hidden area
  • Mold flow analysis before steel cutting: fill balance, weld line position, air trap, cooling layout
  • Multi circuit mold temperature control, independent loops for the deep optical zone and the thin flange
  • Venting designed per flow analysis to avoid burn marks and short shots on a low flow material

Tool data

  • Mold size up to 2500 x 1600 mm, mold weight up to 25 tons
  • Tool life 300,000 to 500,000 shots, with regrind and re-polish service
  • T0 samples: 6 to 8 weeks after design freeze and steel order
  • Sampling report: dimensions, light transmission, haze, weld line and gate mark photos

Commercial terms

  • Price: USD 1 as reference unit, project quoted by part size, cavity number and steel selection
  • MOQ: no MOQ, one tool or one trial order accepted
  • DFM and mold flow report: 5 to 7 days after receiving the 3D data

The problems we design around

  • Large height difference. The optical zone is deep and the flange is thin, so melt arriving late in the deep zone cools fast. Sequential valve gate timing and a balanced hot runner are used to keep pressure and temperature even across the part.
  • Poor flow of PC. High viscosity means high injection pressure and short flow length. Gates are placed on the thickest section, venting is generous, and the cooling layout avoids chilling the flow front.
  • Weld lines and flow marks. In a transparent lens a weld line is a visible defect. Gate position and sequence are chosen so the line lands on a hidden rib or behind the bezel.
  • Residual stress and birefringence. Uneven packing shows as rainbow bands under polarized light. We balance packing pressure, hold time and mold temperature, and check samples under a polariscope.
  • Corrosion from PC. PC releases aggressive volatiles at melt temperature. Cavity inserts are hardened, nitrided or made in stainless where the gas path runs.
  • Optical geometry. The faceted surface is the light distribution surface, so the cavity cannot be hand polished into shape. 5 axis cutting plus controlled polishing keeps the designed profile.

Quality and documentation

  • IATF 16949 workshop, PPAP documentation available on request
  • Steel certificates, heat treatment records and hardness reports per mold
  • First article inspection, mold flow report and sampling video delivered with the tool

We build lamp lens molds, lamp housing molds, light guide and reflector molds, and the production parts that come off them. Common searches from our buyers: automotive headlight lens mold, car lamp mold manufacturer, PMMA lens injection mold, PC transparent mold, optical lens tooling China, LED headlight mold maker, large automotive injection mold, 5 axis mold machining, hot runner valve gate mold, H13 ESR lens mold, XPM mold steel, IATF 16949 mold supplier, tail lamp lens mold, two shot lamp housing mold, mold flow analysis service, low volume trial mold, automotive tooling China.

Send the 3D data, the molded material and the optical requirement, and we will reply with a DFM and mold flow plan, the steel proposal, the cavity layout and the T0 schedule.

No comment

Product Overview

Automotive Headlight Lens Injection Mold

This is a production injection mold for a transparent automotive lamp lens, molded in optical PMMA or impact modified PC. The photo shows the cavity block of a headlight lens tool: two curved lens pockets with the fine faceted optics that shape the light beam, plus the runner and ejector layout around them.

Lens tools are not built like ordinary housings. The cavity has a large height difference between the deep optical zones and the thin outer flange, the two materials flow badly, and any weld line, flow mark or residual stress shows up immediately as an optical defect. The tool therefore has to be machined, polished, tempered and vented to a much tighter standard than a structural part.

Applications

  • Headlamp outer lens and inner lens
  • Tail lamp and rear combination lamp lenses
  • Daytime running light and fog lamp lenses
  • Turn signal and position lamp covers
  • Two shot lamp housings with hard coat
Technical Specifications

Molded material

  • PMMA optical grade, high light transmission, mold temperature 80 to 100 C
  • PC impact modified, high viscosity and poor flow, mold temperature 90 to 120 C
  • Wall thickness 1.5 mm to 4.0 mm, deep optical zone against thin flange

Mold steel

  • Cavity and core: XPM pre hardened plastic mold steel, about 38 to 42 HRC, high polishability for optical surfaces
  • High wear and high load inserts: 1.2344 ESR (H13 ESR), hardened and tempered to 48 to 52 HRC, vacuum quenching
  • Sliders, lifters and wear plates: 1.2344 ESR or S136 hardened, nitrided where the melt is aggressive

Machining and finishing

  • All curved cavity surfaces cut on 5 axis high speed machining centers, no hand blending on the optical zone
  • Surface profile tolerance plus minus 0.02 mm, polishing allowance controlled to keep the optical geometry
  • Optical polish to SPI A1 / A0, no visible tool marks under a light beam
  • Blue light 3D scanning and color map report on the cavity before assembly

Runner and temperature control

  • Hot runner with valve gate, 2 to 8 drops sequenced to move the weld line into a hidden area
  • Mold flow analysis before steel cutting: fill balance, weld line position, air trap, cooling layout
  • Multi circuit mold temperature control, independent loops for the deep optical zone and the thin flange
  • Venting designed per flow analysis to avoid burn marks and short shots on a low flow material

Tool data

  • Mold size up to 2500 x 1600 mm, mold weight up to 25 tons
  • Tool life 300,000 to 500,000 shots, with regrind and re-polish service
  • T0 samples: 6 to 8 weeks after design freeze and steel order
  • Sampling report: dimensions, light transmission, haze, weld line and gate mark photos

Commercial terms

  • Price: USD 1 as reference unit, project quoted by part size, cavity number and steel selection
  • MOQ: no MOQ, one tool or one trial order accepted
  • DFM and mold flow report: 5 to 7 days after receiving the 3D data
Why Lens Molds Are Difficult

The problems we design around

  • Large height difference. The optical zone is deep and the flange is thin, so melt arriving late in the deep zone cools fast. Sequential valve gate timing and a balanced hot runner are used to keep pressure and temperature even across the part.
  • Poor flow of PC. High viscosity means high injection pressure and short flow length. Gates are placed on the thickest section, venting is generous, and the cooling layout avoids chilling the flow front.
  • Weld lines and flow marks. In a transparent lens a weld line is a visible defect. Gate position and sequence are chosen so the line lands on a hidden rib or behind the bezel.
  • Residual stress and birefringence. Uneven packing shows as rainbow bands under polarized light. We balance packing pressure, hold time and mold temperature, and check samples under a polariscope.
  • Corrosion from PC. PC releases aggressive volatiles at melt temperature. Cavity inserts are hardened, nitrided or made in stainless where the gas path runs.
  • Optical geometry. The faceted surface is the light distribution surface, so the cavity cannot be hand polished into shape. 5 axis cutting plus controlled polishing keeps the designed profile.

Quality and documentation

  • IATF 16949 workshop, PPAP documentation available on request
  • Steel certificates, heat treatment records and hardness reports per mold
  • First article inspection, mold flow report and sampling video delivered with the tool
Related Custom Services

We build lamp lens molds, lamp housing molds, light guide and reflector molds, and the production parts that come off them. Common searches from our buyers: automotive headlight lens mold, car lamp mold manufacturer, PMMA lens injection mold, PC transparent mold, optical lens tooling China, LED headlight mold maker, large automotive injection mold, 5 axis mold machining, hot runner valve gate mold, H13 ESR lens mold, XPM mold steel, IATF 16949 mold supplier, tail lamp lens mold, two shot lamp housing mold, mold flow analysis service, low volume trial mold, automotive tooling China.

Send the 3D data, the molded material and the optical requirement, and we will reply with a DFM and mold flow plan, the steel proposal, the cavity layout and the T0 schedule.

Automotive Headlight Lens Injection Mold - PMMA PC Transparent Lamp Tooling
Headlight and lamp lens injection molds for transparent PMMA and PC. Large height difference cavities cut on 5-axis machines, XPM pre-hardened and 1.2344 ESR hardened tool steel, hot runner with valve gate sequencing, optical grade polish, T0 samples in 6 to 8 weeks.
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