We utilize conformal cooling channels in molds for thick lenses to prevent optical stress birefringence and reduce cycle times by 15%.
We hold tolerances as tight as ±0.01mm on critical optical paths and assembly interfaces to ensure perfect light transmission.
Our dry-air conveying systems prevent moisture absorption in hygroscopic resins, eliminating bubbles and silver streaks in your clear parts.
We provide quotes within 24 hours, analyzing critical factors for transparent plastics, such as refractive index, haze value, and UV stability. We help select the optimal resin (e.g., Mitsubishi Iupilon vs. Covestro Makrolon) based on your optical and cost targets.
Our DFM focuses on preventing cosmetic defects. We strategically place gates to avoid weld lines on visible surfaces and design overflow traps to catch air bubbles. 3D mold design includes flow analysis to ensure complete cavity filling without shear stress.
Mold construction utilizes high-speed CNC and precision grinding on premium steels (S136, NAK80). The core and cavity undergo hand-polishing by master technicians to achieve an SPI-A1/A2 mirror finish, essential for flawless transparency.
The first trial validates optical clarity. We inspect samples for haze, bubbles, and sink marks. 5-10 defect-free samples are sent to you for evaluation of light transmission and dimensional accuracy.
If issues like silver streaks (moisture) or flow marks appear, we adjust injection speed, pressure, and mold venting. We refine the mold until the part is optically pure and structurally sound.
Mass production uses dehumidifying dryers and hopper loaders to prevent moisture regain. We implement inline visual inspection to reject any parts with scratches or contamination, ensuring batch-to-batch consistency.
To prevent scratches on high-gloss surfaces, parts are packed in anti-scratch sleeves or custom EPE foam, not standard PE bags. Cleanroom packaging is available for medical-grade components.
Molds are stored in our temperature-controlled vault. Before reorders, we re-polish the optical surfaces and check gate wear to restore the original mirror finish, ensuring your replacement lenses remain crystal clear.
Please free no hesitation to ask questions.
A: We support low-volume prototyping and mass production. MOQ starts from 1 set of mold.
A: Yes, we protect your IP with strict NDAs and secure data storage.
“Finding a molder who understands optical clarity is tough. ACO Mold’s expertise with PC resins ensured our underwater camera housing was completely free of bubbles and distortions, even under deep pressure. Their SPI-A1 polishing made the difference between a good product and a great one.”
