Writing in the journal Applied Optics , published by Optica Publishing Group , researchers from Tunghai University in Taiwan compared 3D printing technology with traditional manufacturing methods such as computer numerical control (CNC) machining and reverse engineering in the production of headlight lenses.
Recent research has highlighted the benefits of using 3D printing technology to manufacture headlight lenses. The findings suggest that additive manufacturing can overcome the limitations of traditional manufacturing processes, allowing for greater flexibility and efficiency in the production of a wide range of products.
Traditional manufacturing methods have limitations such as high cost, long delivery time, low productivity, etc. This research uses headlight lenses as a case study to explore the potential of 3D printing to replace traditional manufacturing methods, aiming to create a faster product validation process in the industry.
Ye Chiahong, Research Leader and Professor at Tokai University
Not only does 3D printing produce superior precision and surface quality, it has also proven to be more efficient to manufacture and cost-effective than traditional methods.
3D printing technology has great potential in the manufacturing of optical components by enabling rapid prototyping of product designs, allowing designers and engineers to quickly validate the aesthetic, structural and functional aspects of their creations. Furthermore, it helps realize complex and innovative designs, shorten the development cycle of new vehicle models and increase their overall competitiveness in the market.
Weimin Chen, PhD student at Tokai University
Meeting the needs of today’s manufacturing industry
The optical plastics industry has evolved to become increasingly focused on offering a wide range of products and serving specific customer needs. This change has seen the traditional mass production model, which prioritized consistent quality, replaced by smaller production batches and more customized solutions.
The high cost of traditional lens molds requires manufacturers to carefully evaluate the financial risks and benefits before starting production, often resulting in a lengthy decision-making process.
“Moreover, as product designs become more complex, the mold designs and manufacturing processes also become more complex, slowing down production speeds,” Ye said. To stay competitive in a rapidly changing marketplace, manufacturing design capabilities must quickly respond to these needs. “
In the current study, the researchers compared reverse engineering and CNC machining with 3D printing, two techniques widely used in manufacturing optical components. The team used a headlight lens as a case study, selected appropriate materials and processes based on the actual requirements, and produced test products using each method.
Compare processes
The researchers assessed the manufacturing results by analyzing key aspects of the headlight lenses, including light transmittance, surface profile, radius of curvature, diameter, height, and surface roughness. The 3D printed lenses have 93% light transmittance, excellent surface roughness, and minimal radius of curvature error.
This performance exceeds the 90% light transmission of a commercially available polycarbonate lens and is comparable to the CNC machined sample (94%) and two reverse engineered lenses (91% and 94%).
The team produced 14 headlight lenses in an eight-hour print cycle using approximately $30 in plastic material, demonstrating that 3D printing can not only support the production of one-off prototype designs, but also improve operational efficiency and reduce production times for small-batch mass production.
” 3D printing offers key advantages, including the integration of multiple components into one structure, reducing manufacturing costs and simplifying assembly. Overall, 3D printing in optical applications offers increased design flexibility, cost efficiency and sustainability, positioning itself as a driver of transformation in the industry as the technology continues to evolve, ” Yeh noted.
While the study looked at different headlight lens manufacturing techniques, further research is needed to evaluate the performance of the lenses in real-world settings. To ensure the results can be successfully applied to real-world settings, the researchers plan to investigate specific headlight module combinations and evaluate internal factors such as fixed temperature, operating environment, and structural design.
Journal References:
Yeung, C.-H. and Lin, H.-Y. (2025) Using 3D printing technology to replace the manufacturing process of headlight lenses. Applied Optics . Translation:
