3D printing shines in overcoming headlight lens manufacturing challenges

13 January 2025

3D printing shines in overcoming headlight lens manufacturing challenges

WASHINGTON - A recent study has demonstrated the benefits of using 3D printing to make headlight lenses. The results highlight the ability of additive manufacturing to overcome the limitations of traditional manufacturing methods for greater flexibility and better performance in manufacturing a variety of product types.

"Traditional manufacturing methods come with limitations such as high costs, long delivery times and low yield," said research team leader Chia-Hung Yeh from Tunghai University in Taiwan. "This study uses a headlight lens as a case study to explore the potential of 3D printing as an alternative to traditional manufacturing methods, aiming to create a faster product verification process for the industry."

In the Optica Publishing Group journal Applied Optics, the researchers compared 3D printing with the traditional manufacturing approaches of Computer Numerical Control (CNC) machining and reverse engineering for producing headlight lenses. They found that 3D printing not only achieved exceptional precision and surface quality but also outperformed traditional methods in production efficiency and cost-effectiveness.

"3D-printing technology holds significant promise for producing optical components by allowing rapid prototyping of product designs, enabling designers and engineers to quickly validate the aesthetic, structural and functional aspects of their creations," said Wei-Min Chen, a doctoral candidate who helped lead the research with Yeh. "Additionally, it makes it possible to bring intricate and innovative designs to life, shortening the development cycle for new vehicle models and boosting overall market competitiveness."

Meeting today's manufacturing needs

As the optical plastic industry has evolved, the market has gradually shifted to a stronger emphasis on offering diverse products and meeting customized needs. The traditional model of mass production, which focuses on consistent quality, has been replaced by a move toward smaller batches and more personalized solutions. The high cost of traditional lens molds requires manufacturers to carefully evaluate the financial risks and benefits before committing to production, leading to longer decision-making processes.

"Moreover, as product designs become more complex, mold design and manufacturing processes are also becoming more intricate, which slows production speeds," said Yeh. "To stay competitive in a rapidly changing market, manufacturing design capabilities must meet these demands quickly."

In the new study, the researchers used a headlight lens as a case study for applying 3D printing technology to production while comparing it with CNC machining and reverse engineering, which are commonly used methods for making optical components. After selecting appropriate processes and materials based on real-world requirements, the researchers fabricated test products using the various production processes.

Process comparison

The researchers evaluated the manufacturing results by measuring key properties of the headlight lens, including light transmittance, surface profile, radius of curvature, diameter, height and surface roughness. The 3D-printed lens demonstrated a minimal curvature radius error, exceptional surface roughness, and a transmittance of 93%. This was comparable to the transmittance of the CNC-machined sample (94%) and the two types of reverse-engineered lenses (91% and 94%), while exceeding the 90% transmittance of a commercially available polycarbonate lens.

For the tests, the researchers were able to produce 14 headlight lenses in a single 8-hour print cycle, with a resin material cost of approximately $30 USD. This showed that 3D printing is not only effective for making one-off prototype designs but is also suitable to improve operational efficiency and shorten production times for small lot and large variety manufacturing.

"3D printing offers key advantages, such as consolidating multiple components into a single structure, reducing manufacturing costs and simplifying assembly," said Yeh. "Overall, 3D printing in optical applications improves design flexibility, cost efficiency and sustainability, positioning it as a transformative force in the industry as technology continues to advance."

While this study examined various manufacturing processes for headlight lenses, further research is needed to evaluate lens performance under real-world conditions. The researchers plan to investigate specific headlamp module configurations and assess internal factors, such as fixture temperature, operating environment and structural design, to ensure the findings can be effectively translated into practical applications.

Paper: C.-H. Yeh, H.-Y. Lin, "Using 3D Printing Technology to Replace the Manufacturing Process of Headlight Lens," Applied Optics, 64, 488-497 (2025).
DOI: https://doi.org/10.1364/AO.539164

About Optica Publishing Group

Optica Publishing Group is a division of the society, Optica, Advancing Optics and Photonics Worldwide. It publishes the largest collection of peer-reviewed and most-cited content in optics and photonics, including 18 prestigious journals, the society's flagship member magazine, and papers and videos from more than 835 conferences. With over 400,000 journal articles, conference papers and videos to search, discover and access, our publications portfolio represents the full range of research in the field from around the globe.

About Applied Optics

Applied Optics publishes in-depth peer-reviewed content about applications-centered research in optics. These articles cover research in optical technology, photonics, lasers, information processing, sensing, and environmental optics. Optica Publishing Group publishes Applied Optics three times per month and oversees Editor-in-Chief Gisele Bennett, MEPSS LLC. For more information, visit Applied Optics.

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