Technical Information Technical information
Optical Product Design and Manufacturing Technology Technical Detail
Through many years of experience in mould design and manufacturing for aspheric lenses for automotive headlamps, we have accumulated advanced technology and extensive achievements.
We apply our accumulated know-how to the shape data provided by our customers to propose high-precision, high-quality resin optical products.
Aspheric (Freeform) Lenses
We achieve mass production of complex aspheric (freeform) lenses for high-quality, high-precision automotive headlamps using precision mould design and manufacturing technology that pursues shape accuracy within 10μm (micrometres *). We achieve total cost reduction through design, parts, and processes, as well as extending the life of the mould itself through material selection and design that considers distortion.
* μm (micrometre) is a unit of length in the International System of Units (SI), representing one-thousandth of a millimetre.
Microprism Arrays
We perform optical design for microprism arrays for pictogram drawing applications. Pictograms intended to be displayed in a specific position can be drawn at any projection distance using numerous microprisms. Design is possible according to drawing image quality, such as the number of prism cells, angles, and cell size, meeting our customers' needs.
Nanbu Kasei Co., Ltd.'s
Optical Product Design & Manufacturing Technology
Two Features
01
Intricate Design of Microstructure (Fine Shape) Sections
For the fine surface processing that determines the light distribution of lenses, we can handle mould surface roughness of Ra 10nm (nanometres *) or less and surface accuracy of 10μm. We perform intricate designs with this advanced processing technology as our background.
* nm (nanometre) is a unit of length in the International System of Units (SI), representing one-millionth of a millimetre.
02
Maximising Optical Effective Area
By achieving fine shapes through intricate designs based on the use of small-diameter tools and optical-specific CAM (Computer Aided Manufacturing), we maximise the effective area within the specified optical shape, thereby enhancing the performance and quality of optical components.
Application Examples of Nanbu Kasei Co., Ltd.'s
Optical Product Design & Manufacturing Technology
Mass Production of Thick Resin Lenses Using High-Precision Correction Technology
For resin lens products with thick walls, deformation due to post-mould shrinkage after moulding is a challenge. However, with high-precision correction technology at the design and prototyping stages, mass production of lenses with a surface accuracy of 10μm or less has become possible. Furthermore, we have high-precision 3D shape measuring machines for lens evaluation, as well as a 25m darkroom and light distribution evaluation equipment, all in-house, enabling rapid feedback.
Reduction of light loss in micro-prism arrays
We have achieved a surface accuracy of 3μm or less, a surface roughness of Ra10nm or less, and a processing R of 0.03mm or less for the prism surface, thereby reducing light loss in micro-prism arrays. This is applicable to both small-volume production through direct cutting of resin materials and mass production through moulding with dies.
Frequently Asked Questions
Q
What level of optical design can you support?
A
We will respond in the optimal way according to the content.
We basically handle design in-house, but for some special cases, we work with partner manufacturers under confidentiality agreements.
Q
What kind of thick-walled moulded products can you manufacture?
A
It depends on the required precision.
We have experience with maximum wall thicknesses of 25mm and dimensional accuracy of ±0.01mm, but this can vary in either positive or negative directions depending on your required precision. Please consult with us first.
