0.01mm Precision Mould Service | OEM/ODM Auto Lamp Mould for Customization & Polishing

Core Specifications at a Glance

Core Advantages: Precision, Customization & ISO9001-Guaranteed Quality

1. 0.01mm Ultra-Precision: The Foundation of Reliable Auto Lighting

• Optical Feature Fidelity: Replicates micro-structured components (e.g., 0.1mm prism arrays on headlight reflectors, 0.05mm light-guiding grooves on taillight lenses) with 99.8% accuracy, ensuring light beams align with ECE R112 and SAE J578 standards (no glare for oncoming drivers, no dark spots in signal lights).
• Thermal Stability: Uses S136/H13 steel with low thermal expansion coefficient (11.5×10⁻⁶/℃ for S136), maintaining ±0.01mm precision even under high-temperature injection (280–320℃ for PC resins) and repeated thermal cycling—avoiding lamp component warpage that disrupts light distribution.
• High-Precision Machining: Equipped with 5-axis CNC machines (DMG Mori NHX 5000) and Zeiss CMM (±0.0005mm accuracy) for real-time inspection, ensuring every mold cavity meets 0.01mm precision benchmarks before delivery.

2. Tailored Customization & Polishing: 适配 Diverse Lamp Requirements

• Lamp-Specific Polishing:
  • Headlight Reflectors: Mirror polish (Ra ≤0.008μm) to maximize light reflectivity (≥95%), focusing LED light into a sharp, long-range beam.
  • Taillight Diffusers: Semi-matte polish (Ra 0.01–0.02μm) to create uniform light diffusion, ensuring dynamic signal lights (e.g., sequential turn signals) display smoothly without "bright edges".
  • Fog Lights: Anti-glare polish (Ra 0.02μm) to reduce light scatter in low-visibility conditions, enhancing road illumination without dazzling other drivers.
• Design Flexibility: Supports OEM/ODM projects, from initial DFM (Design for Manufacturability) analysis (e.g., optimizing lens wall thickness to avoid sink marks) to custom cavity designs for new energy vehicle integrated lighting (e.g., roof DRL strips, rear light bars).

3. ISO9001 Quality Management: Consistent Performance Across Batches

• Pre-Production Control: Selects S136/H13 steel from ISO9001-certified suppliers, with 100% material composition testing (ICP-MS) to avoid impurities that cause polishing defects.
• In-Process Inspection: Conducts 3 rounds of precision checks (after rough machining, fine machining, and polishing) using CMM and surface roughness testers (Mitutoyo SJ-210), rejecting any mold with precision deviations exceeding 0.005mm.
• Post-Delivery Traceability: Provides comprehensive quality reports for each mold, including material certificates, machining parameters, polishing records, and CMM inspection data—facilitating automakers’ traceability audits and regulatory compliance.

Application Scenarios by Auto Lamp Type

Customization & Technical Support

• Design Collaboration: Our engineering team provides 24-hour DFM analysis for customer-provided lamp designs, optimizing cavity geometry (e.g., adding draft angles for easy demolding) and polishing schemes to balance precision and production efficiency.
• Rapid Prototyping: Delivers 1-cavity prototype molds in 12–15 days, paired with test injections using PC/PMMA resins—validating precision, polishing effect, and light performance before full-scale production.
• Material & Process Matching: Recommends optimal mold materials (S136 for corrosion resistance, H13 for high volume) and resin parameters (injection temperature, cooling time) based on lamp type and production volume, ensuring long-term mold reliability.

Quality & Service Commitment

• Precision Validation: Each mold undergoes 100% dimensional inspection (Zeiss CMM) and polishing quality testing (surface roughness + reflectivity measurement) before shipment.
• Compliance Guarantee: Fully meets ISO9001 standards, with additional compliance support for IATF 16949 (automotive-specific quality management) upon customer request.
• Lifecycle Support: Offers a 1-year warranty for mold defects; provides maintenance guidelines (polishing touch-up, cavity cleaning) to extend mold service life to ≥500,000 cycles.