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.
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.
Aluminum housings are machined with controlled feed rates to maintain flatness and mounting hole concentricity within ±0.01 mm. Surface anodizing protects against corrosion.
Custom jigs and CMM feedback loops ensure optical centerline alignment between lens and housing within 0.02 mm.
We optimize machining programs for low-volume prototypes, ready for scaling to small-batch production without design drift.
Precision, fast turnaround, and zero defects - mechanical engineers rely on DEK when failure is not an option.
Send us your drawing—we’ll provide fast DFM feedback and a precise quote, no minimum order.
