Simulation and experimental study on enhancing dimensional accuracy of polycarbonate light guides

Abstract

This research investigates the adaptation of conventional injection-molding techniques for producing thick-walled polycarbonate optical components, specifically targeting their application in automotive light guides. With the automotive industry’s growing demand for reliable yet cost-efficient optical products, the study examines how traditional injection-molding processes can be refined to enhance dimensional accuracy and reduce defects. Simulations and experimental trials were conducted to evaluate the impact of critical process parameters, such as melt temperature, mold temperature, injection pressure, and gate design, on the overall quality of the final components. The results show that by carefully optimizing these parameters, it is possible to significantly reduce common defects like warpage, surface imperfections, and dimensional instability. This research highlights the potential of existing molding techniques to meet high industry standards while maintaining cost-effectiveness, offering valuable guidance for manufacturers aiming to produce high-quality optical components for demanding applications like automotive lighting.