The Challenge

For a light-transmitting component to function properly, clarity is everything. The part had to be completely clear, without haze, inclusions or surface defects.

The specification pushed the limits of our usual processing range. In truth, it was almost too small for comfortable manufacture. We decided to proceed regardless, partly because we believed it could be achieved and partly to demonstrate that the constraints could be managed.

Tooling was also complex. The size and detail required intricate machining, and EDM time was longer than normal. That had to be factored into planning.

So the challenge wasn’t just clarity. It was precision, scale and practicality.

Our Approach

Material selection was straightforward in principle. We advised the use of polycarbonate, as optical clarity was essential and it offered the necessary transparency and strength for automotive use.

Surface finish then became critical. The component required a high level of polishing to achieve the required light transmission. Any imperfection would be visible once installed.

Because of the size constraints, the tooling had to be adapted carefully. There was no opportunity for a traditional prototype stage. Instead, we moved directly to tooling and produced initial samples from the mould itself.

Those samples met the customer’s requirements and were signed off first time.

Production was then carried out using a fully automatic process to ensure repeatability and consistency.

At Allthread Plastics, smaller and more intricate components often require more attention than larger ones. This was one of those projects.

The Outcome

The component moved successfully into production and remains in ongoing supply.

Despite the tight tolerances and clarity requirements, the finished light tube performed as intended and became part of a completed automotive system.

In practical terms:

• A bespoke, injection moulded polycarbonate solution
• Successful first-time sample approval
• Ongoing manufacture at relatively small production volumes

The project demonstrated that even at the smaller end of the processing range, a workable and commercially viable solution was possible.

Materials and Production Details

• Material: Polycarbonate
• Manufacturing method: Injection moulding
• Processing: Fully automatic production
• Design basis: Bespoke component developed to meet optical clarity requirements

Key Takeaway