High Precision Custom 2 Cavity PC UV Protected LED Spotlight Lens Injection Mold

This high-precision custom injection mold is specially engineered for manufacturing outdoor spotlight optical lenses from UV-stabilized polycarbonate (PC). Built as a 2-cavity 3-plate pin point gate mold with 1.2344 hot work steel, both cavity and core undergo professional optical polishing to achieve flawless transparent surfaces. The mold is optimized to eliminate common defects for clear PC parts, ensuring consistent optical performance, high light transmittance and long-term weather resistance for outdoor LED lighting lenses.

Mold Specifications

Key Advantages

✅ Optical Polished 1.2344 Mold Steel1.2344 (H13 equivalent) hot work steel hardened to HRC48-52 delivers superior wear resistance and thermal stability. Both sides of the mold are finely optical polished, transferring mirror smooth finish to transparent PC lenses, avoiding scratches, orange peel and light scattering, and securing high light transmission. It supports long continuous mass production with low maintenance.

✅ 3-Plate Pin Point Gate Design for Optical SurfacesPin point gate leaves minimal gate vestige and automatically separates from the lens during ejection without manual trimming. It prevents scratching or damaging the critical optical curved surface, maintaining the original light focusing effect of the spotlight lens.

✅ Mold Optimized for UV Resistant Transparent PCTransparent PC mixed with UV additives is prone to silver streaks, bubbles, burn marks and internal stress. We optimize mold flow path, venting slots and cooling balance to suppress these molding defects, reducing residual stress and preventing lens yellowing and deformation under long-time outdoor UV exposure.

✅ Ultra-precise Dimensional & Optical ControlWe reserve 0.5% shrinkage rate matched for PC material. High-precision CNC and EDM machining strictly controls the curved optical profile, ensuring stable light distribution and consistent focal performance across every molded lens.

✅ Uniform Cooling System to Reduce Residual StressWell-designed cooling channels maintain stable and even mold temperature, shorten molding cycle time and greatly lower internal residual stress, effectively avoiding warpage, birefringence and optical distortion of transparent polycarbonate lenses.

Our Full Custom Mold Service

We provide one-stop mold solution covering DFM analysis, mold flow simulation, optical polishing, mold fabrication, mold trial, sample inspection and after-sales mold maintenance. Before mold shipment, we carry out strict inspection on optical surface quality and dimension tolerance to guarantee stable mass production for LED lighting customers.

Application Range

Custom optical lens injection molds for outdoor spotlights, landscape lamps, floodlights, downlights and all kinds of LED luminaire transparent optical components, suitable for outdoor weather-resistant lighting projects.

FAQ

Q1: Why optical polishing is required for this PC lens mold?A1: Mold surface texture is directly replicated onto transparent PC lens. Optical polishing removes micro scratches and surface imperfections, ensuring high light transmittance and uniform light output of finished lenses.

Q2: What molding difficulties does UV resistant transparent PC have?A2: UV additives and clear PC easily produce gas marks, silver lines and internal stress. Our optimized venting and cooling design solves these issues and protects lenses from outdoor UV aging and yellowing.

Q3: Can you make molds according to customer’s 3D optical drawings?A3: Yes. We accept custom mold development based on your 2D/3D optical drawings or physical samples. DFM and mold flow simulation will be implemented in early stage to evaluate filling risk and optical performance.