Optical Castings: Various Sizes & Customization for Specific Optical Designs

Core Specifications at a Glance

Core Advantages: Customization, Size Versatility & Optical Integrity

1. Customization for Specific Optical Designs: Precision in Every Detail

• Complex Feature Replication: Replicate intricate optical details—from 3μm anti-reflective textures and 10μm prism facets to free-form lens curvatures and micro-structured diffusers—with 99.9% fidelity. This ensures light behaves as designed, whether for uniform backlighting in displays, sharp focusing in camera lenses, or precise beam shaping in medical lasers.
• Design Alignment: Our engineering team collaborates with your optical designers to optimize casting parameters (e.g., mold flow, cooling rates, and material selection) for your specific design, ensuring the final casting retains critical optical properties like refractive index consistency and minimal aberration.
• Performance Validation: Pre-production simulations (ray tracing, mold flow analysis) verify that castings meet light transmission, diffusion, or guidance targets, reducing trial-and-error and accelerating time-to-market.

2. Various Sizes: Scalability for Diverse Optical Applications

• Micro-Optics: Castings for compact components (φ1–10mm) such as fiber optic connectors, micro-LED lenses, and sensor optics, with precision to handle sub-10μm features (e.g., light-guiding grooves or micro-prisms).
• Medium-Format: Solutions for consumer and medical optics (10–200mm), including smartphone camera lenses, VR headset optics, and endoscope light guides, with multi-cavity casting options to boost production efficiency for high-volume needs.
• Large-Format: Castings for industrial and automotive applications (200–1200mm), such as automotive headlight lenses, solar concentrator panels, and industrial illumination light guides, with controlled cooling to prevent warpage in large, thin-walled structures.

3. Optical-Grade Quality: Materials & Processes for Clarity

• High-Clarity Materials: Use optical-grade resins (PMMA for superior clarity, PC for impact resistance, COC/COP for low birefringence) and glass-reinforced composites (for thermal stability), ensuring castings transmit light with minimal absorption or haze.
• Precision Casting Techniques: Advanced molding processes (injection casting, compression casting) with vacuum degassing eliminate air bubbles and voids—critical for maintaining light transmittance (≥92% for PMMA/PC) and preventing optical defects.
• Surface Finish Excellence: Post-casting polishing (Ra ≤0.005μm) and anti-reflective coatings enhance light transmission and reduce glare, making castings ideal for high-performance optics like machine vision lenses or surgical microscope components.

Application Scenarios by Optical Industry Segment

Customization & Technical Support

• Design Collaboration: Our optical engineers provide DFM (Design for Manufacturability) insights to refine your design for casting, optimizing features like wall thickness, draft angles, and texture placement to preserve optical performance.
• Rapid Prototyping: Size-specific prototypes in 10–15 days, using production-grade materials to validate optical clarity, dimensional accuracy, and light behavior before full-scale production.
• Material Matching: Recommend optimal resins or composites based on your application’s needs (e.g., heat resistance for automotive, biocompatibility for medical, or low birefringence for laser optics).

Quality & Service Commitment

• Optical Inspection: Each casting undergoes 3D optical scanning (resolution 0.01μm), haze/transmittance testing, and birefringence analysis to verify compliance with design specs.
• Certifications: Compliant with ISO 9001, with full traceability for materials, design files, and performance data.
• Lifecycle Support: Provide guidelines for handling, cleaning, and maintenance to preserve optical integrity, ensuring long-term performance in end applications.

Heya Precision: Factory Overview & Production Excellence

Factory Basics: Location & Scale

• Strategic Location: Based in Dongguan, China’s core precision manufacturing hub—enabling efficient access to raw material suppliers, logistics networks, and global shipping ports (Shenzhen/Hong Kong), ensuring timely delivery for international clients.
• Optimized Space: Over 1000㎡ of dedicated production area, divided into functional zones (precision machining, electroforming, plastic molding, surface treatment, and quality inspection) to streamline workflows and minimize cross-contamination risks.
• Compliant Environment: Adheres to industrial safety and environmental standards, with well-ventilated workspaces, anti-static flooring in precision zones, and organized storage for mold components—reflecting our commitment to orderly, professional production.

Production Capabilities: Equipment & Processes

• Precision Machining Zone: Hosts high-speed CNC engraving machines (for intricate mold details) and multi-axis CNC machining centers—capable of handling complex mold geometries with dimensional tolerance as tight as ±0.005mm, critical for electroformed mold cores.
• Surface Treatment Zone: Features in-house mold texturing (pattern etching) and brushing finish equipment—eliminating reliance on third-party vendors to reduce lead times. We also offer outsourced texturing/brushing services for external mold manufacturers, showcasing our flexible capabilities.
• Plastic Molding Zone: Includes injection molding machines tailored for small-to-medium volume plastic parts, compatible with diverse resins (PC, PMMA, ABS) commonly used in automotive, electronics, and consumer goods industries.

Team & Quality Control

• Skilled Workforce: A 30+ team of experienced professionals, including 5+ senior mold engineers (with 10+ years in precision machining), 12+ certified technicians, and dedicated quality inspectors—ensuring every stage (from raw material intake to final mold testing) meets Heya Precision’s standards.
• End-to-End Quality Checks: Embeds strict inspection checkpoints:
  • Raw material verification (mold steel, resins) with supplier certificates;
  • In-process testing (CMM measurements for machining accuracy, surface roughness tests for texturing);
  • Final validation (mold trial runs, dimensional sampling) before shipment.

Support for OEM/ODM

• Flexible Production Lines: Accommodate small-batch prototype orders (e.g., 1–10 mold cores) and medium-volume production (100–5,000 plastic parts) without compromising precision.
• Collaborative Workflow: Dedicates project managers to OEM/ODM clients, ensuring clear communication between your team and our factory—from design confirmation (DFM analysis) to production scheduling and post-delivery support.