Plastic LED Lens Injection Molding Production Manufacturer
Experienced LED Lens Manufacturer for Street Light
From the sectional view of the bulb in the 3D product image, we can see that the original design of the lens is a solid bulge with a flat bottom. And the maximum thickness has reached 9mm. This is obviously a first-generation lens with a simple structure. It seems that the previously led lens manufacturer didn’t understand enough about optical refraction. Such a product structure is a big challenge for the injection molding process.
In the past, the customer has made lens molds in other optical lens factories, but unfortunately, many lens injection molding defects happened, such as flow lines, air bubbles and so on. When the client showed us the product he got, he directly described it as “horrible”, and he was very worried that he would lose the project if it went on like this.
In the above picture, it is obvious that the molten plastic has serious bond line problems after molding and cooling. And the position of these bond lines happens to appear on the most important sphere, which is obviously unacceptable. The reason for this undesirable phenomenon is the unreasonable design of the injection mold and the defective analysis of the mold flow, which leads to poor control of the bonding line.
The client visited our factory for the first time in August 2013. At that time, the “peanut rice” bulb structure has become popular in China’s LED street lamp lens industry. So in face-to-face communication with them, we suggest that they improve the design of this raised bulb. The “peanut” structure can not only reduce the weight of the product for lower manufacturing costs but also improve the optical effect. The new design is more conducive to injection molding of high-quality plastic LED lenses.
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 injection molding 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
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 and hot runner. For LED street light lens products, the answer given by our experience is that a hot runner is an unnecessary option. 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.
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.
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. The rich experience in injection molding of this transparent PC material helps us to manufacture high-quality street light lenses better and more efficiently.
Optical Effect Verification of LED Street Light Lens Manufacturing
Optical grade PC1250Z plastic raw material as the raw material of LED lens
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