Production Process
The quality of a reflector directly depends on the precision of the electroform insert used during plastic injection molding. Only a well-engineered electroform insert can ensure that the reflector fulfills its intended warning function and meets regulatory photometric standards.
Expertise in PIN polishing, PIN alignment, and electroforming technology is essential to producing high-performance electroform inserts—these are highly specialized processes that represent significant technical barriers.
Taiwan K-Lite is among the few electroform insert mold suppliers in the world with over a decade of experience in design evaluation and production. We continuously refine our processes and are proud to deliver top-tier electroform inserts. Once we undertake a project, we commit to ensuring full compliance with certification requirements.
Feasibility
We carefully evaluate each reflector electroform insert development case and offer free feasibility assessments. Taiwan K-Lite conducts a comprehensive analysis based on key factors such as reflective area, applicable regulatory standards, and product installation location.
This early-stage evaluation helps identify potential blind spots and prevent failures in regulatory compliance later in development.
If you have a reflector electroform mold insert development request, please click the link below to complete our Feasibility Form and contact us at sales@k-lite.com.tw Our team will promptly assess your requirements and provide a detailed feasibility report.
PIN Processing & Polishing Technique
Taiwan K-Lite possesses comprehensive in-house capabilities covering the entire process—from PIN fabrication and precision polishing to electroforming. By utilizing finely polished PINs as the master material, we are able to produce high-performance reflective electroform inserts that meet the most demanding optical requirements.
- Surface roughness of polished PINs can be controlled to under 0.1 μm
- Utilizes 2.38 mm hexagonal PINs, aligning with modern optical and aesthetic design trends
- Proprietary polishing technology ensures exceptional reflective performance
3D CAD Design and Electroform Insert Fabrication
We begin each project by developing precise 3D CAD models based on customer drawings or design requirements. These digital models serve as the foundation for the physical electroform insert manufacturing process. Our experienced engineering team ensures that every detail—from optical surface geometry to mold integration—is accurately reflected in the final insert.
This digital-to-physical workflow not only improves production accuracy, but also shortens development lead time and ensures compatibility with customer tooling and lighting systems.
PIN Arrangement and Fixation Based on 3D Model
Following the finalized 3D CAD model, the hexagonal PINs are meticulously arranged and fixed onto the base mold in precise alignment with the optical design specifications. This step is critical, as it determines the structure and performance of the final electroform insert.
Each PIN must be positioned with exact spacing, orientation, and depth to ensure optimal reflective geometry. The fixation process is carried out with high-precision fixtures and measurement tools to avoid distortion or misalignment during the subsequent electroforming stage.
Proper PIN layout and secure fixation form the foundation for achieving uniform microstructures and consistent photometric performance in the final reflector product.
Nickel Growth Through Electroforming
During the electroforming process, nickel ions are gradually deposited onto the surface of the arranged PINs, accurately replicating the hexagonal geometry of each PIN. This electrochemical reaction forms the detailed microstructure required for high-performance reflectors.
Electroforming is a time-intensive and highly controlled process. To achieve a thickness of 10 mm, the reaction typically requires 3 to 5 weeks of continuous nickel deposition under stable current, temperature, and electrolyte conditions. The slow growth ensures uniform density, minimal internal stress, and high structural integrity of the electroform insert.
This meticulous process is what enables the electroform to maintain its optical precision and long-term durability in production environments.