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Precision Manufacturing for Custom Headlight Prototypes

DEK manufactures headlight prototypes from optical-grade plastics like PC and PMMA. We utilize 5-axis CNC machining for complex geometries and advanced polishing techniques to achieve superior optical clarity and fitment. Trusted by automotive OEMs. ISO/IATF certified.
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Prototypes de phares
Introduction

Precision Machining for Complex Headlight Prototypes

Precision Machining for Complex Headlight Prototypes

Automotive headlight prototypes require high accuracy in lens curvature, optical clarity, and mounting interface alignment. Achieving consistent optical surfaces without distortion is a primary challenge.

At DEK, we use multi-axis CNC and precision fixturing to maintain ±0.01 mm on metal housings and optical-grade smoothness on lenses. Our team applies controlled polishing methods and surface protection during machining.

We verify curvature and alignment using CMM, optical comparators, and surface roughness testers, ensuring both optical performance and dimensional stability.

Demande de prix

±0.01 mm tolerance

stable in production

Ra 0.05 µm

optical surface finish

300 mm lens size

maximum clear diameter

Multi-material

metal + PMMA machining
capabilities

Capacités d'usinage

Optical Lens Surface Polishing

We machine PMMA or PC lenses on 5-axis CNC, followed by precision polishing to achieve Ra 0.05 µm. Vapor polishing is used for final optical clarity.

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Complex Housing Machining

Aluminum housings are machined with controlled feed rates to maintain flatness and mounting hole concentricity within ±0.01 mm. Surface anodizing protects against corrosion.

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Curvature and Alignment Control

Custom jigs and CMM feedback loops ensure optical centerline alignment between lens and housing within 0.02 mm.

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Prototype-to-Production Transition

We optimize machining programs for low-volume prototypes, ready for scaling to small-batch production without design drift.

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Dimensional Verification with CMM and Optical Tools

We use CMM and optical projectors to verify lens curvature, housing geometry, and runout. Each prototype includes a measurement report.
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Automotive Material Compliance

All polymers and metals meet RoHS and automotive-grade standards. Certificates of conformity are supplied for each lot.
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Assembly Fit Testing

Trial assemblies are conducted in-house to confirm fit between lens, housing, and brackets before shipment.
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Protective Export Packaging

Each prototype is packaged with lens film, foam inserts, and fumigation-free crates for transport.
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TESTIMONIALS

Témoignages

“The lens clarity was exactly what we needed for beam testing.”
Mark Jensen, Optical Engineer
“Tolerances were spot on for the bracket alignment, no rework needed.”
Lucas Meyer, Mechanical Engineer
“We received the prototypes in less than two weeks, fully polished.”
Sophie Dubois, Purchasing Manager
“Surface quality matched our optical simulation requirements perfectly.”
David Thompson, R&D Engineer
“The assembly fit right into our test rig without adjustment.”
Erik Svensson, Prototype Engineer
“Packaging was secure, lenses arrived without a single scratch.”
Paolo Ricci, Buyer
“Communication on drawings was clear and fast throughout the process.”
Tom Williams, Project Engineer
“They provided a complete measurement report with every lens.”
Alex Brown, QA Engineer
“Transitioning from prototype to small-batch was seamless.”
Hiroshi Tanaka, Product Engineer
“Anodizing was consistent across all housing parts.”
Mateusz Kowalski, Design Engineer

Ce qui nous différencie

Précision, rapidité d'exécution et absence de défauts - les ingénieurs en mécanique font confiance à DEK lorsque l'échec n'est pas envisageable.

Nous contacter
6–12 h

6–12 h Quote

You receive a detailed, engineer-reviewed quote within half a day.
1 Piece

Low MOQ 1 pc

We start from a single prototype without cost penalties.
10+ yr

10+ yr Engineers

Your parts are handled by specialists in optics and precision machining.
FAQ

Prototypes de phares FAQ sur l'achat

Our engineers review CAD files to select optimal machining and polishing methods, then quote within 6–12 h.
Simple housings: 5–7 days. Full lens + housing assemblies with surface polishing: 10–14 days.
Yes, Ra 0.05 µm via CNC + vapor polishing for PMMA/PC lenses.
We use optical comparators and CMM to confirm curvature against CAD profiles.
Yes, we machine metals and plastics separately, then conduct trial fits before shipment.
Yes, RoHS and automotive-grade certificates for all supplied materials.
Each lens is film-wrapped, foam-protected, and packed in fumigation-free wooden crates.
Yes, we update toolpaths and fixtures quickly to incorporate changes without starting over.
Yes, we sign NDAs before file exchange to ensure confidentiality.
Yes, our processes meet ISO 9001 and IATF 16949 standards for automotive components.

Put Your Headlight Prototypes into Production Today

Send us your drawing—we’ll provide fast DFM feedback and a precise quote, no minimum order.

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DEK
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