Asahi Optics is a leading Chinese manufacturer specializing in the design and production of high-quality optical lens molds.
The molds we produce can be used in the production of optical lenses in areas such as street lighting, indoor lighting and automotive lighting.
Our Optical Lens Mold Manufacturing Process
We define the production of optical lens molds as four key stages: optical design, mold structure design, prototype mold (sampling) and hard mold (mass production). Every detail of each step cannot be ignored, this is Asahi's attitude towards mold production.
1. Optical Design
In order to customize the efficiency of optical design, we need to determine the specific development specifications of the optical lens with you before the design begins, including optical lens drawings, lens materials (PC/PMMA), lighting design files (Dialux, Relux, AGI, IES), LED specifications, PCB layout and lamp assembly drawings
After getting the requirements, Asahi's optical engineers use advanced software (LightTools/TracePro) to simulate and optimize lens performance. The final design will be converted into a 3D model and an IES file will be generated for lighting performance verification.
2 Mold structure design
After ensuring the perfection of the optical design, engineers will transform the optical design into a functional mold structure through 3D software (SolidWorks, UG/NX).
The key components of the mold structure include the core and cavity (molding surface), mold base and cooling system (for temperature control), and ejection mechanism (for part removal).
3 Prototype mold (sample)
Before the final step of mass production, we will make a prototype mold. This prototype mold is generally made of economical materials, such as aluminum or low-carbon steel. The service life is generally to produce 50-500 samples, which will be used to test the optical performance of the lens.
4 Hard Mold (Mass Production)
Hard mold (mass production) The final production mold needs to meet the requirements of long-term mass production, so it needs to undergo strict quality control. After ensuring that the prototype mold and sample are approved, we will develop the hard mold (mass production)!
Step 1: Precision Machining
Rough Machining: CNC milling/lathing shapes the mold with a 01–03mm allowance for finishing
Heat Treatment: Hardening (HRC 50–60) improves durability
Fine Machining:
Diamond turning/grinding achieves nanometer-level surface accuracy
EDM (Electrical Discharge Machining) creates complex microstructures
Step 2: Polishing & Coating
Polishing: Mechanical/chemical polishing ensures a mirror finish
Coating: DLC or nickel plating enhances wear resistance
Step 3: Quality Inspection
Surface Accuracy: Interferometers (Zygo) check for λ/4 deviations
Roughness: AFM or white-light interferometers verify Ra < 10nm
Dimensions: CMM measures critical tolerances
Step 4: Trial Molding & Adjustments
Test shots are produced using optical-grade plastics (PMMA, PC)
Lenses are tested for clarity, light distribution, and defects
Step 5: Mass Production & Maintenance
High-volume injection molding with optimized parameters
Regular maintenance extends mold life beyond 300,000 shots
