Project: Car Dashboard Lenses with Excellent Polishing Performance
Client: Leading Automotive Tier 1 Supplier | Industry: Automotive Lighting | Timeline: 5 Weeks
Project Overview
Our customer, a leading Tier 1 automotive supplier, approached TakumiTech® with a challenging project: producing car dashboard lenses that required exceptional surface finish and optical clarity. These lenses would be installed in premium vehicle dashboard displays, where any defect would be immediately visible to the end user.
The lenses needed to meet strict automotive industry standards for optical performance, durability, and aesthetic quality. The project required not only precision molding but also advanced mold polishing techniques to achieve the required surface finish.
Technical Challenges
This project presented several significant technical challenges that required innovative solutions:
- Optical Clarity: Achieving glass-like transparency without haze, cloudiness, or internal stresses
- Surface Finish: SPI A1 diamond polish finish (Ra < 0.012μm) for mirror-like appearance
- Dimensional Accuracy: Tight tolerances of ±0.05mm for perfect fit in dashboard assembly
- UV Resistance: Long-term resistance to yellowing and degradation from sunlight exposure
- High Volume Production: Consistent quality across 50,000+ units at production speeds
- Contamination Control: Zero tolerance for black specs, dust particles, or foreign material
Our Engineering Solution
TakumiTech® assembled a cross-functional team of mold designers, process engineers, and quality specialists to tackle this challenge. Our comprehensive solution included:
Mold Design Optimization
We began with advanced mold flow analysis to optimize the mold design for optical quality:
- Simulated material flow to identify and eliminate potential weld lines
- Optimized gate location and size for uniform filling and minimal stress
- Designed conformal cooling channels for uniform temperature distribution
- Selected premium mold steel (S136 ESR) for excellent polishability
Precision Mold Polishing
Our master craftsmen performed meticulous hand polishing to achieve the required surface finish:
- Multi-stage polishing process from 400-grit to diamond paste
- SPI A1 finish achieved through expert hand polishing techniques
- Surface roughness measured at Ra 0.008μm (better than required)
- Final polish performed in cleanroom environment to prevent contamination
Process Control
Precision process control ensured consistent quality throughout production:
- Computer-controlled injection parameters with real-time monitoring
- Precision temperature control (±1°C) for consistent material properties
- Dry air drying to prevent moisture-related defects
- Automated part removal to prevent surface damage
Quality Assurance
Comprehensive quality control at every stage of production:
- 100% visual inspection under controlled lighting conditions
- Automated optical inspection (AOI) for defect detection
- Dimensional inspection with CMM for critical features
- Light transmission and haze measurement for optical quality
- Cleanroom packaging to maintain quality during shipping
Project Results
The project was delivered successfully, exceeding customer expectations in all key metrics:
- Lead Time: 5 weeks from design approval to first samples (2 weeks faster than competitor quotes)
- Quality Rate: 99.8% first-pass yield (industry average: 95-97%)
- Production Volume: 50,000+ units produced with consistent quality
- Surface Finish: SPI A1 achieved and maintained throughout production
- Customer Satisfaction: Zero quality complaints after 6 months in production
- Cost Savings: 18% cost reduction compared to customer’s previous supplier
Customer Testimonial
“TakumiTech® exceeded our expectations in every way. The optical quality of the dashboard lenses was outstanding, and the consistency across 50,000+ units was remarkable. Their engineering team provided valuable design insights that improved our product performance. We’ve since awarded them three additional projects.”
— Procurement Director, Tier 1 Automotive Supplier
Key Takeaways
This project demonstrates TakumiTech®’s capability in delivering high-quality optical components for demanding automotive applications. Our combination of advanced engineering, master craftsmanship, and rigorous quality control ensures success even for the most challenging projects.
Whether you need optical lenses, precision components, or high-volume production parts, TakumiTech® has the expertise and equipment to deliver exceptional results.
Have a similar project? Contact us today for a free consultation.