LED Lens Manufacturer – Plastic Injection Molding

Experienced LED Lens Manufacturer for Street Light

The client greatly appreciated our design and advice and hoped that we could salvage his first lens project and apply the new structure to future lens designs. Based on our rich experience in plastic led lens production, our engineers believe that we can completely improve the bonding line problem in the injection molding process according to the customer’s original spherical structure. The customer immediately decided to let us help remanufacture the mold for the first street light lens. After 30 days, we completed the mold manufacturing of this 350*220mm lens as scheduled. We provide beautiful T1 samples to customers. Of course, we got a thumbs up.

After the completion of the first spherical LED lens, starting from the second LED street light lens project, RD customers have adopted the “peanut rice” structure we suggested to him instead of the original bulb structure.

For these larger size LED street light lenses, there is generally no need to manufacture prototypes. The traditional process of making prototypes such as CNC machining and vacuum casting cannot make qualified lens samples. Customers generally directly custom high-precision plastic injection molds for mass production. Therefore, the light distribution process before mold making is particularly important. Only when the computer-simulated optical illumination effect meets the customer’s requirements, the design can be determined to be qualified.

So far, the customer has customized the production of more than 20 “peanut rice” lenses. We have shipped more than two million units to them. This kind of “peanut rice” street light lens makes the customer’s products very competitive. We are very happy that our work is valuable.

Manufacturing Review of LED street light lens

Mold Design

Designing a cooling system requires incorporating mold flow analysis. The designer carefully considers the influence of cooling on the flow of molten plastic, abandons the conventional “#” cooling system thinking, avoids structures such as thimbles, and designs a reasonable cooling water flow route to achieve a reasonable cooling effect.

Selection of cold runner or hot runner. We have done many street light lens molds with a cold runner structure. This not only helps customers save tooling costs but also saves tooling time. The direct injection method also facilitates us to adjust the injection molding process and obtain qualified test samples faster.

Precision Injection Mold Building

It is not good to use regular die steel or regular CNC machining for mold making of LED lenses. The injection molds must be made of S136H steel with the same A-grade quality, using ultra-high-speed and high-precision mechanical engraving, and using Sodick mirror EDM to process the subtle structure, and then super-mirror polishing, and finally produce a qualified precision mold core.

Since the precision control of the mold processing process is very strict, the later mold assembly and adaptation are relatively easy. Our mold engineers only need to pay attention to the proper alignment of the parting surfaces after the mold core and mold base are assembled.

Transparent Injection Molding Production

As an experienced LED Lens Manufacturer, we deeply understand the adjustment of injection molding conditions directly affects the quality control of LED lenses. The injection molding machine should choose a special screw for PC raw materials. If the injection molding machine needs to be used for the mass production of LED street light lenses, our company recommends this injection molding machine to inject colored plastics. The flexible opinion is that when necessary, we can disassemble the screw of the injection molding machine and do polishing and electroplating. Injection molding of this transparent plastic material for lenses is also more difficult than ordinary PC, PP and ABS.

Selection and control of temperature and pressure are also important factors. The general LED street light lens is rectangular. We have manufactured lenses longer than 420mm. The longer the length of the lens, the easier the problem of product deformation after injection molding occurs. In order to avoid the problem of appearance deformation, the designer should design some reasonable bone support structures as much as possible when designing the product, and also consider the pre-deformation and set the molding conditions (pressure, holding pressure, cooling time, etc.) It needs to be adjusted based on past experience. Our rich experience in transparent injection molding helps us to manufacture high-quality street light lenses better and more efficiently.

For LED lens injection molding manufacturing, we will use TOSHIBA injection molding machines to ensure quality.

Optical Effect Verification of LED Street Light Lens Manufacturing

Optical grade PC1250Z plastic raw material as the raw material of LED lens

Your One-stop LED Lens Manufacturer for Customization

Sungplastic is a leading provider of on-demand manufacturing services in China. Precision plastic tooling and injection molding are our core, while prototyping and CNC machining can better support the needs of low volume production. We provide plastic injection molding and contract manufacturing in home appliances, consumer goods, electronics, LED lenses, industrial products, automotive, and energy markets.

When you choose Sungplastic, you get a professional partner through the entire production cycle. Timely, professional, and effective communication is always with you, taking your product from concept or drawing to reality.

Hope you enjoyed this case study overview and may have gained some insights that can help you with your next project.
If you are looking for an LED lens manufacturer for your projects, we are always ready to provide a free quote and project review here.