Dual Shot PC Light Guide Injection Molding | Clear & Light-Blocking Two-Shot Optical Part

Product Description

OVERVIEW Custom dual-shot / two-shot injection molded light guide component made with optical-grade PC. The first shot forms a clear transparent substrate to transmit and guide light; the second shot adds a light-blocking color boundary or housing structure to prevent light leakage, define optical paths, and improve contrast. Ideal for LED lighting, automotive interior illumination, backlit panels, and precision optical assemblies. MANUFACTURING SPECIFICATIONS • Process: Dual Shot / Two-Shot Injection Molding / 2K Molding • Material: Optical-grade PC for the transparent light-guide shot; black/colored ABS, PC, or PC+ABS available for the blocking shot • First Shot: Clear PC substrate for high light transmission and low haze • Second Shot: Light-blocking material to seal edges, block stray light, and create structural/visual boundaries • Bonding: Interlocking geometry and optimized melt compatibility for strong two-material bonding • Surface Finish: High-gloss optical surface on light-transmitting areas; matte/textured or polished finish on blocking areas as required • Dimensional Control: Tight tolerance on light-path walls, edge definition, and mating features • Clean Handling: Produced and packed to avoid scratches, dust, and stress marks on optical surfaces KEY ADADVANTAGES • Integrated Light Guide + Light Block: One molded part replaces separate clear lens and black mask/shield components. • Reduced Assembly: Eliminates secondary gluing, ultrasonic welding, or manual insertion of light barriers. • Better Light Control: Blocking shot prevents side glow, light bleed, and unwanted reflection. • Strong Material Bond: Two-shot process creates reliable interlock between transparent and opaque regions. • Consistent Optical Performance: Clear PC shot maintains uniform transmission and minimal distortion. • Cost-Efficient at Volume: Lower labor and fewer secondary operations compared with multi-part assemblies. TYPICAL APPLICATIONS • LED light guides with integrated light-blocking borders • Automotive ambient / interior lighting components • Backlit keypad, display, and panel optical parts • Indicator windows with anti-light-leakage frames • Medical device illumination components • Consumer electronics optical path modules PROCESS NOTE PC must be properly dried before molding to avoid splay and silver streaks. Gate locations and rotation/indexing sequence are optimized to keep weld lines away from critical light-transmitting zones. The second shot is engineered to fully encapsulate or border the clear PC region without inducing excessive stress or warpage. QUALITY ASSURANCE Backlit visual inspection for light leakage, hot spots, haze, and flow marks. Dimensional check of optical paths, wall thickness, and bonding interfaces. Fit-check with mating LED/diffuser components available. FAIR and CMM inspection on request.

Request Quote Customize ← Back to Products