Our Transparent Plastics Injection Molding Services
Elevate your products with our premium transparent plastic injection molding services—specializing in optical-grade molding for lenses, легкие гиды, и точные компоненты. Мы доставляем glass-clear molding with >90% light transmission, low haze, and design flexibility that outperforms glass. Partner with experts in clear polymer injection to turn your optical and transparent part needs into reality—from medical cuvettes to VR headset lenses.
What Is Transparent Plastics Injection Molding?
Transparent plastic injection molding is a specialized manufacturing process focused on creating clear, light-transmitting parts using high-performance polymers. Unlike standard injection molding, which prioritizes strength or cost, optical-grade molding centers on preserving clarity, minimizing defects (like warping or weld lines), and optimizing light transmission.
По своей сути, clear polymer injection transforms amorphous transparent resins (НАПРИМЕР., ПК, ПММА) into precision parts via controlled heating, инъекция, и охлаждение. Наш transparent thermoplastic service simplifies this technology: we explain how light-transmission molding differs from conventional methods—emphasizing its focus on low shear, uniform cooling, and defect-free surfaces to produce see-through plastic parts с <1% haze and consistent optical performance.
Ключевые термины в precision optic molding включать:
- Amorphous Transparent Resins: Non-crystalline polymers (НАПРИМЕР., ПК, ПММА) that maintain clarity (crystalline resins like nylon become opaque).
- Low-Haze Injection: Molding processes that limit light scattering (haze <1%) for sharp, clear optics.
Optical-Grade Molding: Production meeting strict standards for light transmission (>90%) and birefringence (optical distortion <5 nm/cm).
Our Transparent Plastics Molding Capabilities
We offer a comprehensive suite of transparent plastic injection molding capabilities tailored to industries requiring optical clarity and precision. Below is a detailed breakdown of our core strengths:
| Способность | Ключевые функции | Типичные приложения |
| High-Clarity Molding | Достигает >92% световая передача (Лейтенант); haze <0.5%; weld-line free | Оптические линзы, Светодиодные руководства, VR headset optics |
| Multi-Shot Clear Parts | 2–3 shot cycles; bonds clear resins (НАПРИМЕР., ПК) with soft-touch TPE or colored plastics | Consumer electronics windows, 2-shot mask frames |
| Insert Molding Transparent | Integrates metal inserts (НАПРИМЕР., threaded pins) or glass fibers into clear parts; no clarity loss | Sensor covers, automotive lens mounts |
| Clean-Room Molding | Сорт 7 clean rooms; Iso 13485 соответствие; particle count <10,000 particles/ft³ | Medical cuvettes, pharmaceutical packaging |
| Thin-Wall Transparent | Molds parts as thin as 0.3 мм; maintains structural integrity and clarity | Microfluidic chips, thin optical lenses (0.5 mm PC) |
| Micro-Optic Molding | Produces micro-scale features (50 µm channels); precision ±0.005 mm | COC microfluidic devices, miniaturized sensor optics |
| Global Clear Supply | Warehouses in 4 regions (NA, Евросоюз, APAC, MEA); 3–5 day delivery for high-volume orders | Multi-national LED, Автомобиль, and medical brands |
Наш over-molding clear windows capability also lets us add protective or functional layers (НАПРИМЕР., anti-scratch coatings) during molding—streamlining production for parts like smartphone screens.
The Transparent Plastics Injection Molding Process
А transparent plastic injection molding process is a highly controlled sequence optimized to preserve clarity and optical performance. Below is a step-by-step overview with critical parameters:
Шаг 1: Материал подготовка
- Resin Drying: Amorphous transparent resins (НАПРИМЕР., ПК, ПММА) undergo 2–4 hours of drying at 80–100°C to remove moisture (moisture causes cloudiness; critical for >90% LT).
- Обработка смол: Stored in sealed, dry containers to prevent reabsorption before molding.
Шаг 2: Injection Setup
- Расплавлять температуру: 230–320 ° C. (material-dependent: PC = 280–320°C; PMMA = 230–260°C); precise temp control (±5°C) avoids resin degradation.
- Температура формы: 80–120 ° C. (maintained via water or oil heating); uniform temp prevents warping and ensures clear surfaces.
- Screw Design: Low-shear screw design (22:1 L/D ratio) to minimize resin shear (shear causes haze or discoloration).
Шаг 3: Инъекция & Monitoring
- Hot-Runner Valve Gate: Precise flow control; maintains melt temp to avoid cold spots (cold spots create opaque areas).
- Vacuum Venting: Removes trapped air (air bubbles cause clarity defects); reduces scrap rate by 90%.
- Injection Strategy: Slow-fill high-pack (fill speed = 20–30 mm/s; pack pressure = 800–1,000 bar) чтобы избежать турбулентности (turbulence scatters light).
Шаг 4: Охлаждение & Post-Molding
- Uniform Cooling: Coolant flow rate optimized (2–3 L/min) to ensure even cooling; prevents stress-induced birefringence.
- Stress-Relief Anneal: 1–2 hours at 80–100°C (for PC/PMMA) Чтобы уменьшить внутренний стресс; критическое для precision optic molding.
In-Mold Coating: Optional clear protective coating applied during molding (НАПРИМЕР., anti-scratch HC coating); Сохраняет время после обработки.
Transparent Plastics Materials: Options for Optical & Функциональные потребности
Право transparent polymer is key to balancing clarity, производительность, и стоимость. We offer a range of resins tailored to industry requirements:
| Тип материала | Ключевые свойства | Typical Grades | Идеальные приложения |
| PC Polycarbonate | 90% Лейтенант; воздействие (60 KJ /); теплостойкий (130° C HDT) | Lexan™ 121R, Makrolon® 2405 | Автомобильные линзы, consumer electronics windows, VR headsets |
| PMMA Acrylic | 92% Лейтенант; Высокий глянец; рентабельный; царапина (2ЧАС) | Plexiglas® GS, Acrylite® FF | Светодиодные руководства, косметические бутылки, signage lenses |
| COC Cyclic Olefin Copolymer | 91% Лейтенант; low birefringence; биосовместимый | Topas® 5013L, Zeonex® 480R | Microfluidic chips, medical cuvettes, Оптические датчики |
| Tritan™ Copolyester | 90% Лейтенант; Без BPA; Безбелевая посудомоечная машина; воздействие | Tritan™ TX1001, Tritan™ EX401 | Продовольственные контейнеры, baby bottles, reusable drinkware |
| PSU Transparent | 88% Лейтенант; autoclavable (121° C., 200+ цикл); химический устойчивый | Ultrason® S 2010, Radel® R-5100 | Медицинские устройства (Хирургический инструмент ручки), pharmaceutical equipment |
| PET-G | 90% Лейтенант; гибкий; переработана; рентабельный | Eastman™ PET-G 6763, Amcor® PET-G | Cosmetic bottles, упаковка, thin-wall containers |
All materials meet global standards: FDA 21 CFR 177 (food-contact), Iso 10993 (медицинский), и IATF 16949 (Автомобиль).
Surface Treatment for Transparent Plastic Parts
Transparent plastic injection molding parts often need surface treatments to enhance durability, optics, или функциональность. Our options are designed to preserve clarity while adding value:
| Тип лечения | Ключевые функции | Преимущества | Целевые отрасли |
| Diamond-Polish Clear | Раствор < 0.01 мкм; зеркальная отделка; enhances LT by 2–3% | Sharp optics; reduced light scattering | VR lenses, precision optical components |
| Anti-Scratch HC Coating | Твердость: 6ЧАС (карандашный тест); resistant to abrasion | Extends part life; no clarity loss after wear | Smartphone windows, automotive lenses |
| Anti-Reflective (АР) Покрытие | Reduces reflection from 4% к <0.5%; increases LT by 3–5% | Crisper optics; less glare | VR/AR headsets, объективы камеры, LED light guides |
| Anti-Fog Coating | Hydrophilic; prevents condensation; maintains clarity in humid environments | Clear visibility; ideal for medical/automotive use | Medical masks, automotive headlights, холодильники полки |
| UV-Blocking Layer | Блоки 99% of UVA/UVB rays; no yellowing over time | Protects contents (еда, косметика) or users | Продовольственные контейнеры, косметические бутылки, outdoor lighting |
| Laser Engraving Clear | High-resolution (300 DPI); permanent marks; no clarity loss around engravings | Branding, part numbering, safety labels | Медицинские устройства, потребительская электроника, Автомобильные детали |
Key Advantages of Transparent Plastics Injection Molding
Transparent plastic injection molding offers unmatched benefits over traditional materials like glass or commodity plastics. Here’s how it delivers value:
| Преимущество | Performance Metric | Почему это важно |
| Superior Light Transmission | >90% Лейтенант (PC/PMMA/COC); haze <1% | Острый, clear optics for lenses, легкие гиды, and displays |
| Легкий против. Стекло | 50–70% lighter (PC = 1.2 G/CM³; glass = 2.5 G/CM³) | Reduces weight for portable devices (VR headsets) и автомобильные детали (fuel efficiency) |
| Воздействие сопротивления | PC withstands 60 KJ / (10x more than glass); no shattering | Safer for high-use or fragile applications (baby bottles, Автомобильные линзы) |
| Дизайн свободы | Molds complex shapes (НАПРИМЕР., 1m long PMMA light guides, 50 µm COC channels); no post-machining needed | Custom optics and parts that glass can’t match |
| Cost-Effective High-Volume | Tooling costs 30% lower than glass; production cycle time 50% faster | Affordable for mass production (500k+ LED optics/yr) |
| BPA-Free & Переработана | Tritan™, PET-G, and COC are BPA-free; PC/PMMA are recyclable (PCR grades available) | Meets eco-friendly and safety demands |
Industry Applications of Transparent Plastics Injection Molding
Наш transparent plastic injection molding services support diverse industries that rely on clarity, точность, и производительность:
- Оптика & Электроника: Оптические линзы (0.5 mm thin PC with 92% Лейтенант), Светодиодные руководства (1m long PMMA), и VR headset lenses (AR-coated for less glare); critical for sharp visuals in devices.
- Медицинский: Medical cuvettes (COC, биосовместимый), autoclavable PSU parts (Хирургические инструменты), и датчики крышки (прозрачный, химический устойчивый); meets strict sterility and clarity standards.
- Автомобиль: Автомобильные линзы (PC with anti-scratch coating), headlight bezels (multi-shot clear/black), и датчики крышки (воздействие); withstands road debris and temperature swings.
- Еда & Напиток: Продовольственные контейнеры (Tritan™, Без BPA), косметические бутылки (PET-G, переработана), и baby bottles (Безбелевая посудомоечная машина); safe for daily use and compliant with food regulations.
- Аэрокосмическая: Aerospace canopies (ПК, воздействие), cockpit displays (anti-glare AR coating), и sensor optics (low birefringence COC); reliable in extreme altitude conditions.
Потребительские товары: Smartphone windows (anti-scratch HC coating), reusable drinkware (Tritan™), и Косметическая упаковка (PET-G, Высокий глянец); balances durability and aesthetics.
Тематические исследования: Success with Transparent Plastics Molding
Our clients trust us to solve their most challenging transparent part needs. Вот 3 standout projects:
Случай 1: High-Volume LED Light Guides
- Испытание: A global LED manufacturer needed 500k/yr PMMA light guide (1М Лонг) с 92% Лейтенант, no weld lines, and uniform light distribution.
- Решение: Использовал low-shear screw design, vacuum venting, и slow-fill high-pack инъекция; добавлен diamond-polish clear finish to enhance LT.
- Результат: Light guides achieved 93% Лейтенант (1% above target); 99.8% Без дефекта ставка; cost reduced by 20% против. client’s previous supplier; delivered on time for global LED launch.
Случай 2: Medical Microfluidic Chips
- Испытание: A biotech firm needed COC microfluidic chip с 50 µm channels (for DNA testing)—required biocompatibility, 91% Лейтенант, and no leakage.
- Решение: Used Zeonex® 480R (biocompatible COC); реализовано micro-optic molding (precision ±0.005 mm); добавлен plasma treatment to improve fluid flow.
- Результат: Chips passed ISO 10993 biocompatibility tests; channels maintained 50 µm width (no clogging); 100k units delivered for diagnostic kits.
Случай 3: BPA-Free Baby Bottles
- Испытание: A baby product brand needed Tritan™ bottle (250 mL) that passed 1,000 сбрасывание тестов (1m height), was BPA-free, and had 90% LT.
- Решение: Used Tritan™ TX1001 (Без BPA); optimized температура формы (100° C.) Чтобы уменьшить стресс; добавлен anti-scratch HC coating (4H hardness).
Результат: Bottles survived 1,200 сбрасывание тестов (20% above target); met FDA 21 CFR 177.1580 (food-contact); 300k units sold in 6 месяцы.
Why Choose Our Transparent Plastics Injection Molding Services?
We’re more than a supplier—we’re a partner in creating clear, Высокопроизводительные детали. Вот что меня отличает:
- Optical Expertise: 15+ лет в optical-grade molding; our engineers specialize in optimizing LT, reducing haze, and eliminating optical defects (weld lines, birefringence).
- Сертификаты: Iso 13485 (медицинский), IATF 16949 (Автомобиль), and Class 7 clean rooms—critical for regulated industries like medical and pharmaceutical.
- In-House Capabilities: In-house diamond polishing и integrated coating line (АР, HC, anti-fog) let us control quality from molding to finishing.
- Симуляция & Дизайн: CAE optic simulation predicts light flow and clarity before production; DFM support optimizes designs for cost and performance.
- Скорость: Rapid clear prototyping (7-day turnaround for samples); 24/7 production lines for high-volume orders (500k+ units/yr).
- Устойчивость: Мы предлагаем sustainable clear resins (PCR PC/PMMA, recyclable PET-G) and zero-waste initiatives (переработка 95% лома).
Global Support: On-time global logistics (98% on-time rate); warehouses in 4 regions to serve multi-national clients.