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.
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
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.
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.
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.
