High-Transparency PC Lens Housing
A globally recognized lighting brand commissioned Benma to develop a solar-powered flood light housing for outdoor applications. The project included a high-transparency optical lens and a structural housing designed for long-term outdoor exposure.
The customer required the product to meet strict performance targets:
- Light transmittance ≥ 90%
- 168-hour UV resistance test
- 10J impact resistance test
- Stable mass production with consistent optical appearance
These requirements placed high demands on product design, material selection, mold design, and injection molding process control.
Material Selection Strategy
Material selection was the first critical step in the project. Since the product required high impact strength, optical clarity, and UV resistance, polycarbonate (PC) was selected as the base resin.
Our engineering team performed a detailed comparison of material property data sheets and shortlisted three qualified candidates:
- CHI MEI PC-110U (Taiwan)
- LG PC 1303-10C
- Covestro PC 2407-TDS
Each material was evaluated for:
- Impact resistance
- Optical transparency
- Flowability
- UV aging performance
- Process stability in injection molding
This data-driven approach ensured that material decisions were based on engineering validation, not assumptions.
Moldflow Analysis and Risk Prediction
Before mold design, Benma conducted a comprehensive moldflow analysis. This step allowed us to simulate:
- Melt flow behavior
- Gate position optimization
- Weld line risk
- Sink marks and flow hesitation
- Cooling balance and shrinkage
The simulation helped us identify potential surface defects and optical distortion risks common in transparent PC parts.
After reviewing the moldflow report internally, we shared the findings with the customer and confirmed the final gating strategy and parting line layout before proceeding.
Injection Mold Design and Steel Selection
Based on the moldflow results, our mold engineers completed a custom injection mold design optimized for transparent PC processing.
Key mold design considerations included:
- Uniform wall thickness control
- Balanced runner system
- Polished optical cavity surfaces
- Controlled venting to prevent burn marks
- Stable demolding without stress whitening
Since transparent PC is sensitive to corrosion and surface quality, 718H mold steel was selected. This steel provides:
- High hardness stability
- Excellent polishability
- Good corrosion resistance
- Long mold life for mass production
Accelerated Tooling and T0 Trial Management
The customer requested a T0 trial within 30 days, which required precise project coordination.
Benma assigned:
- Dedicated project engineers
- High-speed CNC machining centers
- Priority injection molding machines
This ensured the mold manufacturing schedule stayed on track without compromising quality.
At the T0 trial stage, we prepared all three PC materials for side-by-side testing. This allowed us to compare:
- Cycle time
- Optical appearance
- Impact performance
- Surface consistency
- Production efficiency
After multiple test runs and data evaluation, CHI MEI PC-110U was selected as the final production material.
Injection Molding Process Optimization
Following material confirmation, our team optimized the injection molding process:
- Melt temperature control
- Injection speed profiling
- Holding pressure optimization
- Mold temperature balancing
- Controlled cooling time
These adjustments ensured:
- High transparency
- No flow marks or haze
- Stable dimensions
- Excellent impact resistance
The final product passed all required UV aging and impact tests, and production efficiency exceeded the customer's expectations.
Customer Feedback and Project Outcome
The customer reported excellent results:
- Optical clarity exceeded target requirements
- Impact resistance met 10J specification
- Production yield was high
- Cycle time was stable
- Visual quality was consistent across batches
The project was approved for mass production, and Benma became the customer's long-term injection molding partner for this product line.
Why Customers Choose Benma
- Full in-house mold design and mold manufacturing
- Advanced injection molding process control
- Strong experience with transparent and optical PC parts
- Data-driven engineering decisions
- Fast response and professional customer communication
- ISO9001 and SMETA certified manufacturing system
Conclusion
This solar flood light housing project demonstrates Benma's strength in plastic injection mold development, material engineering, and precision injection molding for demanding outdoor applications.
From material selection and moldflow analysis to mold manufacturing and mass production, every step was executed with technical rigor and customer-focused efficiency.
Call to Action
If you are developing transparent PC lenses, outdoor lighting housings, or high-impact injection molded parts,
Contact Benma today to start your custom mold and injection molding project.
