| Quantity: | |
|---|---|
YIXUN mold
8480419090
| Transparent Material | Key Optical Properties | Mold Design & Process Requirements | Typical Applications |
|---|---|---|---|
| PMMA (Acrylic) | 92% light transmittance; high scratch resistance; cost-effective | - Optical-grade polishing: Cavity Ra ≤ 0.001μm (mirror finish) - Low-shear gating: Pin-point gates to avoid flow marks - Mold temp: 60–80°C; slow cooling to reduce internal stress | Consumer optics (sunglass lenses), display screens, signage |
| PC (Polycarbonate) | 88% light transmittance; high impact resistance; heat-resistant (120°C) | - Hot-runner systems: Temperature-controlled (270–290°C) to prevent material degradation - Stress-relief cooling: Uniform cooling channels to avoid birefringence - High-pressure injection: 1000–1200 bar for bubble-free filling | Automotive headlight lenses, medical face shields, safety goggles |
| COP (Cyclo Olefin Polymer) | 91% light transmittance; ultra-low birefringence; chemical resistance | - Ultra-precision machining: 5-axis CNC + diamond turning for cavity accuracy (±0.002mm) - Cleanroom molding: ISO Class 7 environment to avoid dust contamination - Low-melt temp: 230–250°C to preserve optical purity | Camera lenses, medical diagnostic optics, fiber optic components |
| PETG | 90% light transmittance; excellent toughness; recyclable | - Wide-gate design: Edge gates for uniform flow in thin-walled parts - Mold temp: 40–60°C; fast cooling for high-volume production - Post-mold annealing: Reduces stress-induced haze | Packaging (transparent containers), cosmetic bottles, light diffusers |
Diamond Polishing: Cavities and cores are polished with diamond paste (0.05μm grit) to achieve a mirror-smooth surface (Ra ≤ 0.001μm). This eliminates micro-roughness that causes light scattering and haze.
Anti-Reflective (AR) Coating Option: For high-end lenses, molds can be coated with AR layers to replicate anti-glare properties directly onto parts, eliminating post-processing steps.
Pin-Point Gates: Used for small lenses (≤50mm diameter) to minimize gate marks, which disrupt light transmission. Gates are placed at non-optical areas (e.g., lens edges) whenever possible.
Sequential Valve Gating: For large components (e.g., automotive headlight lenses), this system controls melt flow to avoid weld lines—one of the most common causes of optical distortion in transparent parts.
Conformal Cooling Channels: 3D-printed cooling channels that follow the exact curvature of lens cavities, ensuring uniform temperature distribution (±1°C). This eliminates internal stress, which causes birefringence (double refraction) and reduces optical clarity.
Slow Cooling Cycles: Extended cooling times (20–40s, depending on part thickness) allow polymers to crystallize evenly, preventing stress-induced cracking or haze.
Sealed Mold Design: Molds are engineered with O-ring seals to prevent dust and debris from entering the cavity during molding—critical for medical and camera lenses where even tiny particles ruin performance.
ISO Class 7 Cleanroom Integration: Our molds are compatible with cleanroom production lines, meeting the strict contamination control requirements of optical and medical industries.
Material Drying: Transparent polymers (especially PC and PMMA) absorb moisture, which causes bubbles and haze. Materials are dried at 80–120°C for 2–4 hours before molding to reduce moisture content to <0.02%.
Precision Molding: Melt temperature, injection pressure, and cooling time are calibrated via Moldflow simulation to match the material’s optical requirements. For COP lenses, molding is done in ISO Class 7 cleanrooms to avoid contamination.
Post-Processing:
Annealing: Parts are heated to 80–100°C for 1–2 hours to release internal stress, improving optical stability and scratch resistance.
Anti-Scratch Coating: Optional spray coating for PMMA/PC lenses to enhance durability (passes 4H pencil hardness test).
Light Transmittance Testing: Using a spectrophotometer to verify transmittance rates (e.g., ≥92% for PMMA lenses).
Birefringence Analysis: Polarized light testing to detect internal stress—critical for camera and medical lenses where light distortion is unacceptable.
Dimensional Inspection: CMM (Coordinate Measuring Machine) with optical scanning to verify lens curvature, thickness, and edge accuracy (tolerance ±0.003mm).
Haze & Clarity Testing: Per ASTM D1003 standards to ensure haze values <1% for high-end optical components.
Automotive: Headlight lenses, taillight diffusers, dashboard display covers.
Medical Devices: Endoscope lenses, face shields, diagnostic equipment viewports (ISO 13485 compliant).
Consumer Electronics: Camera lenses, smartphone screen protectors, VR headset optics.
Lighting: LED bulb diffusers, spotlight lenses, optical fiber connectors.
Aerospace: Cockpit display lenses, sensor windows (impact-resistant PC designs).
Optical Expertise: Decades of experience in molding high-clarity parts—we understand the unique challenges of eliminating flow marks, birefringence, and haze.
Material Mastery: Tailored mold designs for PMMA, PC, COP, and PETG to maximize each polymer’s optical potential.
Customization Flexibility: From micro-lenses (≤5mm diameter) to large automotive headlight lenses (≥300mm), we design molds to match your exact part specifications.
Long Mold Life: Premium tool steels (S136, H13) with PVD coating ensure mold life of 1–3 million cycles, even for abrasive transparent polymers.
| Transparent Material | Key Optical Properties | Mold Design & Process Requirements | Typical Applications |
|---|---|---|---|
| PMMA (Acrylic) | 92% light transmittance; high scratch resistance; cost-effective | - Optical-grade polishing: Cavity Ra ≤ 0.001μm (mirror finish) - Low-shear gating: Pin-point gates to avoid flow marks - Mold temp: 60–80°C; slow cooling to reduce internal stress | Consumer optics (sunglass lenses), display screens, signage |
| PC (Polycarbonate) | 88% light transmittance; high impact resistance; heat-resistant (120°C) | - Hot-runner systems: Temperature-controlled (270–290°C) to prevent material degradation - Stress-relief cooling: Uniform cooling channels to avoid birefringence - High-pressure injection: 1000–1200 bar for bubble-free filling | Automotive headlight lenses, medical face shields, safety goggles |
| COP (Cyclo Olefin Polymer) | 91% light transmittance; ultra-low birefringence; chemical resistance | - Ultra-precision machining: 5-axis CNC + diamond turning for cavity accuracy (±0.002mm) - Cleanroom molding: ISO Class 7 environment to avoid dust contamination - Low-melt temp: 230–250°C to preserve optical purity | Camera lenses, medical diagnostic optics, fiber optic components |
| PETG | 90% light transmittance; excellent toughness; recyclable | - Wide-gate design: Edge gates for uniform flow in thin-walled parts - Mold temp: 40–60°C; fast cooling for high-volume production - Post-mold annealing: Reduces stress-induced haze | Packaging (transparent containers), cosmetic bottles, light diffusers |
Diamond Polishing: Cavities and cores are polished with diamond paste (0.05μm grit) to achieve a mirror-smooth surface (Ra ≤ 0.001μm). This eliminates micro-roughness that causes light scattering and haze.
Anti-Reflective (AR) Coating Option: For high-end lenses, molds can be coated with AR layers to replicate anti-glare properties directly onto parts, eliminating post-processing steps.
Pin-Point Gates: Used for small lenses (≤50mm diameter) to minimize gate marks, which disrupt light transmission. Gates are placed at non-optical areas (e.g., lens edges) whenever possible.
Sequential Valve Gating: For large components (e.g., automotive headlight lenses), this system controls melt flow to avoid weld lines—one of the most common causes of optical distortion in transparent parts.
Conformal Cooling Channels: 3D-printed cooling channels that follow the exact curvature of lens cavities, ensuring uniform temperature distribution (±1°C). This eliminates internal stress, which causes birefringence (double refraction) and reduces optical clarity.
Slow Cooling Cycles: Extended cooling times (20–40s, depending on part thickness) allow polymers to crystallize evenly, preventing stress-induced cracking or haze.
Sealed Mold Design: Molds are engineered with O-ring seals to prevent dust and debris from entering the cavity during molding—critical for medical and camera lenses where even tiny particles ruin performance.
ISO Class 7 Cleanroom Integration: Our molds are compatible with cleanroom production lines, meeting the strict contamination control requirements of optical and medical industries.
Material Drying: Transparent polymers (especially PC and PMMA) absorb moisture, which causes bubbles and haze. Materials are dried at 80–120°C for 2–4 hours before molding to reduce moisture content to <0.02%.
Precision Molding: Melt temperature, injection pressure, and cooling time are calibrated via Moldflow simulation to match the material’s optical requirements. For COP lenses, molding is done in ISO Class 7 cleanrooms to avoid contamination.
Post-Processing:
Annealing: Parts are heated to 80–100°C for 1–2 hours to release internal stress, improving optical stability and scratch resistance.
Anti-Scratch Coating: Optional spray coating for PMMA/PC lenses to enhance durability (passes 4H pencil hardness test).
Light Transmittance Testing: Using a spectrophotometer to verify transmittance rates (e.g., ≥92% for PMMA lenses).
Birefringence Analysis: Polarized light testing to detect internal stress—critical for camera and medical lenses where light distortion is unacceptable.
Dimensional Inspection: CMM (Coordinate Measuring Machine) with optical scanning to verify lens curvature, thickness, and edge accuracy (tolerance ±0.003mm).
Haze & Clarity Testing: Per ASTM D1003 standards to ensure haze values <1% for high-end optical components.
Automotive: Headlight lenses, taillight diffusers, dashboard display covers.
Medical Devices: Endoscope lenses, face shields, diagnostic equipment viewports (ISO 13485 compliant).
Consumer Electronics: Camera lenses, smartphone screen protectors, VR headset optics.
Lighting: LED bulb diffusers, spotlight lenses, optical fiber connectors.
Aerospace: Cockpit display lenses, sensor windows (impact-resistant PC designs).
Optical Expertise: Decades of experience in molding high-clarity parts—we understand the unique challenges of eliminating flow marks, birefringence, and haze.
Material Mastery: Tailored mold designs for PMMA, PC, COP, and PETG to maximize each polymer’s optical potential.
Customization Flexibility: From micro-lenses (≤5mm diameter) to large automotive headlight lenses (≥300mm), we design molds to match your exact part specifications.
Long Mold Life: Premium tool steels (S136, H13) with PVD coating ensure mold life of 1–3 million cycles, even for abrasive transparent polymers.
