Customized Optical Designs Light Molds Solutions | Size-Customizable for Diverse Applications

Core Specifications at a Glance

Core Advantages: Precision, Customization & Optical Performance

1. Tailored Optical Designs for Targeted Light Control

• Intricate Feature Replication: Replicate micro-optical structures (e.g., 5μm light-diffusing dots, 10μm prism ridges, or free-form light guides) with 99.9% accuracy, ensuring precise light refraction, reflection, or diffusion as designed. This is critical for applications like smartphone flash lenses (uniform brightness) or automotive HUDs (sharp light projection).
• Distortion Minimization: Advanced mold flow simulation (using optical-grade software) optimizes cavity geometry to reduce material shrinkage and birefringence, keeping optical distortion below 1%—essential for clear lenses or medical imaging components.
• Design Collaboration: Our optical engineers work with your team to refine designs (e.g., adjusting light guide thickness or diffuser pattern density) for moldability, ensuring the final part matches optical performance targets.

2. Size Customization: From Micro to Large-Format Optics

• Micro-Optics: Molds for tiny components (φ3–10mm) like sensor lenses, fiber optic connectors, or micro-LED light guides, with precision to handle sub-10μm features.
• Medium-Format: Solutions for consumer electronics (e.g., 20–100mm tablet backlight guides, smartwatch display lenses) and automotive interior lighting (door panel light strips).
• Large-Format: Molds for industrial lighting panels (300×500mm), automotive headlight housings, or medical light therapy panels, with uniform cooling to prevent warpage in large surfaces.
• Multi-Cavity Options: Custom multi-cavity molds for small to medium sizes (e.g., 4–8 cavities for smartphone lenses) to boost production efficiency without sacrificing precision.

3. Optical-Grade Materials & Surfaces for Clear Performance

• High-Purity Steel: Uses S136 (corrosion-resistant) or NAK80 (pre-hardened) steel, polished to Ra ≤0.005μm mirror finish—ensuring molded parts (PMMA, PC, optical-grade PP) have blemish-free surfaces that transmit light without scatter.
• Release Optimization: Specialized anti-stick coatings (compatible with optical resins) prevent surface defects like "orange peel" or micro-scratches, critical for maintaining light transmittance (≥92% for PC/PMMA parts).
• Thermal Stability: Steel’s high thermal conductivity, paired with custom cooling channels, ensures uniform resin cooling—preventing internal stresses that cause optical distortion in thick-walled parts (e.g., 5–10mm lenses).

Application Scenarios by Industry

Customization & Technical Support

• Design Validation: 3D optical simulation (ray tracing) to verify light performance before mold production, reducing trial-and-error cycles by 40%.
• Rapid Prototyping: Size-specific prototype molds in 10–15 days, using optical-grade resins to test light transmission, uniformity, and fit.
• Material Matching: Optimize mold design for your optical resin (e.g., PMMA for clarity, PC for impact resistance, COC for UV stability) to maximize performance.

Quality & Service Commitment

• Optical Inspection: Each mold undergoes 3D optical profiling (resolution 0.01μm) and interferometry to verify surface flatness and feature accuracy.
• Compliance: Meets ISO 9001 standards, with material traceability and optical performance reports for regulatory compliance.
• Lifecycle Support: Provide maintenance guidelines to preserve mirror finishes and optical precision, ensuring consistent light performance over 1,000,000+ cycles.

Heya Precision: Factory Overview & Production Excellence

Factory Basics: Location & Scale

• Strategic Location: Based in Dongguan, China’s core precision manufacturing hub—enabling efficient access to raw material suppliers, logistics networks, and global shipping ports (Shenzhen/Hong Kong), ensuring timely delivery for international clients.
• Optimized Space: Over 1000㎡ of dedicated production area, divided into functional zones (precision machining, electroforming, plastic molding, surface treatment, and quality inspection) to streamline workflows and minimize cross-contamination risks.
• Compliant Environment: Adheres to industrial safety and environmental standards, with well-ventilated workspaces, anti-static flooring in precision zones, and organized storage for mold components—reflecting our commitment to orderly, professional production.

Production Capabilities: Equipment & Processes

• Precision Machining Zone: Hosts high-speed CNC engraving machines (for intricate mold details) and multi-axis CNC machining centers—capable of handling complex mold geometries with dimensional tolerance as tight as ±0.005mm, critical for electroformed mold cores.
• Surface Treatment Zone: Features in-house mold texturing (pattern etching) and brushing finish equipment—eliminating reliance on third-party vendors to reduce lead times. We also offer outsourced texturing/brushing services for external mold manufacturers, showcasing our flexible capabilities.
• Plastic Molding Zone: Includes injection molding machines tailored for small-to-medium volume plastic parts, compatible with diverse resins (PC, PMMA, ABS) commonly used in automotive, electronics, and consumer goods industries.

Team & Quality Control

• Skilled Workforce: A 30+ team of experienced professionals, including 5+ senior mold engineers (with 10+ years in precision machining), 12+ certified technicians, and dedicated quality inspectors—ensuring every stage (from raw material intake to final mold testing) meets Heya Precision’s standards.
• End-to-End Quality Checks: Embeds strict inspection checkpoints:
  • Raw material verification (mold steel, resins) with supplier certificates;
  • In-process testing (CMM measurements for machining accuracy, surface roughness tests for texturing);
  • Final validation (mold trial runs, dimensional sampling) before shipment.

Support for OEM/ODM

• Flexible Production Lines: Accommodate small-batch prototype orders (e.g., 1–10 mold cores) and medium-volume production (100–5,000 plastic parts) without compromising precision.
• Collaborative Workflow: Dedicates project managers to OEM/ODM clients, ensuring clear communication between your team and our factory—from design confirmation (DFM analysis) to production scheduling and post-delivery support.