Customer Requirements
What the customer needed
The customer is a global optical product manufacturer producing:LED light guide platesSmartphone camera componentsAutomotive headlamp lensesDisplay diffusion panelsAnnual production:
Case Study
Mold & Die Case Study 12 / 15Optical Mold Machining Case Study
Optical molds are used to manufacture components that control, reflect, or transmit light.
optical mold machining case studymold die cnc machiningcnc machine for mold manufacturing
Project Overview
Standard case data fields.
Industry Optical / Precision Mold & Die
Product Optical Injection Mold
Material S136 / NAK80 / 1.2343 / Optical Steel
Process Ultra-Precision CNC + EDM + Mirror Polishing + Laser Measurement
Machine Model HYR VMC850 (Ultra-Precision Config)
Tolerance +/-0.001-0.003 mm
Surface Finish Ra0.05-0.2 (Optical Grade)
Application Lens / Light Guide Plate / Display Components / Automotive Lighting
Challenges
Machining difficulty
Optical molds combine:Nano-Level Surface Finish+Ultra-Precision Geometry+Light Behavior Engineering+Zero Defect RequirementBecause it requires nano-level surface quality and zero defects.
HYR CNC Solution
Machine configuration
Machine: HYR VMC or gantry CNC system selected according to mold size, steel hardness and accuracy target
Process: Rough machining, stress relief, semi-finishing, EDM support, polishing preparation and inspection
Accuracy Control: Thermal stability, fixture rigidity, finishing allowance control and CMM inspection
Cost Method: Published with existing website assets first to keep implementation cost low
Machining Process
Timeline from raw material to inspection.
01 Material preparation
02 Rough machining
03 Stress relief
04 Finish machining
05 Inspection
Full Case Article
Machining background, difficulty and solution logic.
Quick Facts
Item
Details
Industry Optical / Precision Mold & Die Product Optical Injection Mold Materials S136 / NAK80 / 1.2343 / Optical Steel Process Ultra-Precision CNC + EDM + Mirror Polishing + Laser Measurement Machine HYR VMC850 (Ultra-Precision Config) Tolerance +/-0.001-0.003 mm Surface Finish Ra0.05-0.2 (Optical Grade) Application Lens / Light Guide Plate / Display Components / Automotive Lighting
Introduction
Optical molds are used to manufacture components that control, reflect, or transmit light.
Unlike standard molds: Industrial Mold -> FunctionalityOptical Mold -> Light Behavior Control They directly determine: Light clarity Diffusion pattern Optical uniformity Visual quality
What Is An Optical Mold?
An optical mold is a high-precision injection mold used to produce optical-grade plastic components with controlled light behavior.
Optical Mold BaseUltra-Precision CoreOptical Cavity SurfaceMicro Texture SurfaceMirror Polished Interface
Light Transmitting Material InjectionControlled CoolingSurface Optical ReplicationFinal Light Behavior Output
Typical structure: During production:
Customer Background
The customer is a global optical product manufacturer producing: LED light guide plates Smartphone camera components Automotive headlamp lenses Display diffusion panels Annual production: 200M+ optical components per year Key requirements: Zero optical distortion Uniform light diffusion Nano-level surface precision Absolute consistency No visible machining marks
Why Optical Mold Machining Is Extremely Difficult
Nano-Level Surface Finish+Ultra-Precision Geometry+Light Behavior Engineering+Zero Defect Requirement
Optical molds combine:
Challenge 1
Nano Surface Finish Requirement Optical surfaces require: Ra 0.05 - 0.2 Even microscopic scratches cause: Light scattering Visual distortion Product rejection
Challenge 2
Any defect becomes visible under light.
Mirror-Level Surface Control Surface must behave like: Optical mirror Light diffusion layer Transparent interface
Challenge 3
Micro-Geometry Precision Optical structures include: Micro lens arrays Light guide patterns Diffusion micro dots Tolerance: +/-0.001 mm level control
Challenge 4
Material Optical Stability Materials must ensure: Transparency UV resistance Low distortion
Light Guide Plate Mold
Function: Even Light Distribution Across Surface Used in: TVs Monitors LED panels
Automotive Lens Mold
Function: Headlight Beam Control Used in: LED headlights Taillights
Diffusion Plate Mold
Function: Light Softening & Uniformity Used in: Displays Backlight systems
Micro Lens Array Mold
Function: Optical Focusing & Imaging Control Used in: AR/VR Camera modules
S136 Steel
Advantages: Mirror Polish CapabilityHigh Corrosion ResistanceOptical Stability
NAK80
Advantages: Excellent Mirror FinishStable Machining Behavior
1.2343 Steel
Advantages: High Thermal StabilityGood Wear Resistance
Optical Grade Steel
Advantages: Ultra-High Surface Finish Capability
HYR VMC850 Ultra-Precision
Best for: Micro optical surfaces Lens structures High-precision cavity finishing Key features: Vibration control Thermal stability system High-speed micro finishing
Step 1
Optical Material Preparation Pre-polished steel blocks Stress-free materials
Step 2
Ultra-Fine Rough Machining Remove: 50-70% Material (Controlled)
Step 3
Stress Relief Treatment Eliminate: Micro deformation Internal stress
Step 4
High-Precision CNC Finishing Requirement: +/-0.001-0.003 mm
Step 5
Micro EDM Processing Used for: Micro textures Optical patterns
Step 6
Mirror Polishing Process Achieve: Ra 0.05-0.2 Optical Grade Surface
Step 7
Laser Surface Inspection Ensures: No micro scratches No surface deviation
Optical Surface Measurement
Ensures: Light reflection consistency Surface uniformity
CMM Nano Inspection
Ensures: Geometry accuracy Micro deviation control
Light Simulation Test
Ensures: Optical performance validation
Results
Item
After HYR CNC optimization: Before After Surface Quality Ra0.4 Ra0.05-0.2 Optical Uniformity Medium High Defect Rate 2.0% 0.05% Light Consistency Inconsistent Stable Yield Rate 85% 98%+
Industrial Impact
They define the visual world quality standard.
Optical molds directly affect: Display quality Automotive lighting safety Camera performance AR/VR experience
HYR VMC850 Ultra Precision
Optical lens & micro structures
HYR VMC1060
Large optical plates & lighting systems
Related Articles
Medical Mold Machining Case Study Injection Mold Machining Case Study Hot Runner Mold Case Study Die Casting Mold Machining Case Study Mold Core Machining Case Study
What is an optical mold?
A high-precision mold used to control and shape light behavior in plastic components.
Why is it difficult?
Because it requires nano-level surface quality and zero defects.
What materials are used?
S136, NAK80, 1.2343, optical steel.
What is the main challenge?
Achieving mirror-level surfaces without microscopic defects.
Conclusion
Optical molds represent the highest level of surface precision manufacturing.
They require nano-scale accuracy, perfect mirror finishing, and strict optical performance control.
With ultra-precision CNC machining capability, HYR CNC delivers world-class optical mold solutions for advanced lighting and imaging industries.
Results
Before and after machining improvement.
| Item | Before | After |
|---|---|---|
| Result 1 | Before optimization | After HYR CNC optimization: |
| Result 2 | Before optimization | Surface Quality |
| Result 3 | Before optimization | Ra0.4 |
FAQ
Common buyer questions for this case.
What is this mold case about?
This page covers optical injection mold requirements, machining difficulty, process planning and machine selection.
Which machines are recommended?
HYR VMC850, VMC1060, VMC1165 and gantry CNC systems are selected according to mold size and machining difficulty.
Can HYR-CNC support similar mold projects?
Yes. Send drawings, mold steel, tolerance, surface finish and mold size for a suitable machining proposal.
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