We specialize in manufacturing LED light guides, lampshades, and display bezels using optical-grade PC and PMMA. By precisely mixing light-diffusing additives, we control light transmission and haze effects to achieve your desired luminosity—from crystal clear to soft frosted. Surface finishes range from mirror polishing (Ra<0.05μm) for reflectors to fine VDI textures for aesthetic covers.
We utilize conformal cooling channels in molds for thick-walled lenses to prevent optical distortion and reduce cycle times by up to 15%.
We maintain micron-level precision on light guide prisms and snap-fit joints to ensure consistent illumination and secure assembly.
Our vacuum drying and dehumidifying systems prevent moisture absorption in hygroscopic resins (like PC/PMMA), eliminating bubbles and clouding in transparent parts.
We provide quotes within 24 hours, analyzing critical factors for lighting products, such as light transmittance (%), diffusion angles, and UL94 flammability ratings. We recommend the optimal resin (e.g., Bayer Makrolon™ vs. Mitsubishi Iupilon™) based on your optical and budget requirements.
Our DFM report focuses on preventing cosmetic defects. We analyze gate locations to avoid weld lines on visible surfaces and design overflow wells to trap trapped air in transparent parts. 3D mold design includes optical simulation to predict light paths.
We employ high-speed CNC machining and precision grinding to achieve optical-grade surface finishes (SPI #A1-A3). For complex lens molds, micro-polishing is performed manually to eliminate micro-scratches that scatter light.
The first trial validates optical clarity. We inspect samples for haze levels, surface gloss, and dimensional stability. 5-10 samples are sent for your evaluation, including light output testing if required.
Common issues like silver streaks (moisture) or sink marks on ribs are resolved by adjusting melt temperature and mold venting. We fine-tune the mold until the part is optically flawless and structurally sound.
Mass production adheres to strict IPQC (In-Process Quality Control) standards. We use dehumidifying dryers throughout the process to prevent moisture regain in hygroscopic resins, ensuring batch-to-batch consistency in transparency.
To prevent scratches on high-gloss surfaces, parts are packed in anti-scratch sleeves or custom EPE foam instead of standard PE bags. Anti-static packaging is used for electronic lighting assemblies.
Molds are stored in our temperature-controlled vault. Before reorders, we inspect gate wear and polish cavities to restore the original optical finish, ensuring your replacement light covers remain crystal clear.
“I am very impressed with Aco mold, because the first project we gave them failed, and we should also be responsible for the failure of that project, but Aco mold offered to refund the full amount to us regardless of the time and effort they’ve put in, this was really appreciated. Then my next mold requirements I came to them again.
From the beginning of our cooperation in 2017 to the present, I am really happy with the service they offer. Sometimes things don’t work out how we expect, but I believe that they will surely find a satisfactory solution for us.
I am still referring Aco mold to my fellow maker friends, their service is really fantastic. ”
“Sourcing a molder who understands light diffusion is rare. ACO Mold’s expertise with PMMA blends allowed us to achieve a perfectly uniform glow in our smart lamps without hotspots. Their DFM advice on wall thickness distribution was invaluable. We now rely on them for all our LED light pipe projects.”
