Using 3D printing technology to replace the manufacturing process of a headlight lens

The injection molding technology remains the predominant method for manufacturing plastic optical components; the market is currently trending towards features such as small-batch and diversified production, a streamlined development process, reduced costs, and swift delivery. The conventional production model faces challenges related to production flow, mold cost assessments, expenses associated with hiring skilled professionals, and even a scarcity of talent. Against this backdrop, it is imperative to explore potential solutions that can swiftly replace traditional manufacturing processes in order to address these issues. In this study, we evaluated the feasibility of a headlight lens manufactured using a 3D printing process. The results indicate that the lens products manufactured through 3D printing exhibit remarkable precision, with only a 0.558% margin of error regarding the radius of curvature of the profile, a surface roughness (Ra value) of 0.020175 µm, and a transmittance of 92.54%. One of the key advantages of the 3D printing process is its ability to efficiently realize complex structural designs at high speed and low cost. In cases where customization is required, 3D printing unquestionably outperforms conventional manufacturing methods.