Precision CNC Milling for Automotive Reflectors

An integral aspect of an innovative lighting system is the optical design of automotive lamp reflectors. Even with increasing machining and manufacturing challenges, we provide processing services that meet your ground-breaking design.

Combining the ability of 5-axis CNC ultra-precision milling and machining experience for complex surfaces allows us to focus on every optical detail of the reflector design, overcoming your most challenging needs.

CNC machining aluminum parts - AutoProtoWay
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Manufacturing details about prototype auto reflectors

Here is a breakdown of the client’s needs:

  • Project: Aluminium Reflector for optical test purposes
  • Material: Aluminium 7075 or 7022
  • Technology: CNC milling or micro-milling
  • Details: Milling radius for optical surfaces close to CAD data, R0.1, or R0.15 mm
  • Quality: mirror-polished surface finish, Ra0.05μm, scanned surface accuracy ±0.05mm
  • Quantity: 1 left, 1 right
Precision 5-axis CNC milling

To ensure the best surface finish quality under proper milling conditions, a minimum of split machining may be allowed, otherwise the overall machining is appropriate. Ball-end mills and even diamond mills are used for finishing optical surfaces, while ensuring that the machining of inner radii is within R0.15mm.

Hand mirror polishing

Polishing and metallization are optional processes. We measure the surface roughness to check its quality before proceeding to the next step. Once complete, the final roughness reaches Ra (μm) 0.025-0.05, and exposed sharp edges can be rounded max up to R0.1mm.

Measurement and scanning

We perform 3D scans and roughness measurement twice – after machining and hand polishing. CNC milled roughness is Ra(μm) 0.2, polished final roughness is Ra(μm) 0.05. The surface accuracy tolerance of all process scans is within ±0.05mm.

MORE ABOUT OPTICAL PROTOTYPING

This is an excellent company! I personally enjoyed the energy and the professional support the whole team gave to us into manufacturing aluminum refletors.

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Offering you more than the machined parts.

We pride ourselves on supporting our customers with advanced excellence in optical component design, development and manufacture.

We offer complete support and services at every level, whether it is a styling review, structural optimization, optical testing for various applications, or even a show car project.

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