Customized Automobile Headlight Mould | 0.01mm Precision | OEM/ODM Service

OEM vs. ODM Service Comparison

Core Advantages: 0.01mm Precision & Automotive-Grade Performance

1. Ultra-Precision for Optical Excellence

• Micron-Level Control: With ±0.01mm dimensional tolerance and Ra ≤0.008μm surface finish, our moulds replicate intricate optical features—such as 0.1mm micro-prism arrays (for light distribution) and curved lens surfaces (for beam shaping)—with 99.9% fidelity. This eliminates light distortion, ensuring headlights meet ECE R112 beam pattern standards.
• Optical Simulation Integration: Using 3D ray-tracing software, we validate mould designs to ensure light transmittance (≥92% for PC lenses) and uniform beam distribution, critical for adaptive and matrix headlights.

2. Durability for High-Volume Production

• Premium Materials: S136 steel (resistant to corrosion from PC/PMMA resins) and H13 steel (withstands 280–320°C molding temperatures) ensure moulds endure ≥500,000 cycles without wear.
• Advanced Surface Treatment: Nitride coating (0.005mm thickness) enhances hardness (50–55 HRC) and reduces friction, minimizing resin adhesion and extending maintenance intervals.

3. Customization for Diverse Headlight Designs

• Design Flexibility: Supports complex geometries, including 3D curved lenses, multi-cavity reflectors, and integrated light guides—compatible with LED, matrix, and adaptive headlight systems.
• Tooling Optimization: Conformal cooling channels (designed via CFD) reduce cycle time by 18%, balancing precision with productivity for mass production (10,000+ units/month).

Application Scenarios

• LED Headlights: Precision replication of lens curvatures and heat sink integration features.
• Matrix Headlights: Micro-cavity moulds for 0.5mm pixelated light sources, ensuring accurate beam splitting.
• Adaptive Headlights: Moulds for dynamic lens mechanisms, with tight tolerances to prevent light leakage.
• Halogen Headlights: Heat-resistant moulds for high-temperature resin components (e.g., reflector housings).

Our Service Process

1. Design Collaboration: For OEM, we review client 3D models and perform DFM analysis to optimize mouldability; for ODM, our optical engineers design headlight components from concept.
2. Prototype Validation: 3D-printed prototypes (SLA) for design testing, followed by a 1-cavity trial mould to verify precision and optical performance.
3. Mass Production: Full-scale mould manufacturing (multi-cavity options) with in-line CMM inspection (±0.001mm accuracy) to ensure consistency.
4. Lifecycle Support: Mold maintenance guidelines, process parameter optimization, and rework services to extend tool life.