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Plastic Instead of Glass

New Multi-Layered Lenses for LED Headlights

Temperatures inside the multi-layered structure, during the filling oft he third component (intersectional view), Project Optisys (© Simcon)

An increasing share of of luxury segment and midsize cars use LED headlights. Because LEDs generate less heat than classic incandescent bulbs, this has created an opportunity to replace glass elements in the lenses with lighter and less expensive lenses made of translucent plastic, which meet the same optical requirements as their glass counterparts. In project Optisys, Simcon, a technology leader in injection moulding simulation, collaborated with world-leading automotive industry suppliers to develop multi-layered glass-free lenses for LED headlights.

Micro-structures on the surface of the lens

The key development objectives of project Optisys were to use microstructures to improve the scattering of light, while reducing the volume and size of lenses, using the principles of Fresnel lenses. These microstructures are generated on the surface of the part during the injection molding process, using geometries that are engraved directly into the mold. Simcon developed the capability to model these structures specifically for project Optisys. Going forward, Simcon is now offering this kind of simulation as a service. This functionality is also being integrated into Simcon’s injection moulding simulation solution CADMOULD.

High optical quality of the lenses through multi-step injection molding process

The high optical quality of the lenses is achieved using a multi-layered structure comprised of different materials, such as PMMA and PMMI. To optimize the design of this thick, multilayered free-form lens, Simcon deployed the optimization solution Varimos, which is fully integrated with CADMOULD. It harnesses the speed and accuracy of CADMOULD’s simulation engine to rapidly explore different combinations of parameters in an automated fashion, and then mathematically optimize part geometry and production parameters. “In this way, the artificial intelligence integrated in Varimos automatically explores and learns the impact of different parameters like thickness of layers, gate locations, injection temperatures. And then it computes the optimal solution, based on what it has learned.”, explains Max Mades, project manager at Simcon.

In project Optisys, Simcon collaborated closely with several partners including Hella GmbH & Co. KgaA, a world-leading supplier of headlights and lighting systems, KrausMaffei Group GmbH, a global producer of machinery for the production and processing of plastics, and the Fraunhofer Institute for Material Mechanics IWM. The project was supported by the German Federal Ministry of Education and Research (BMBF).

Additional information
  • 11-06-2019

    Timo Hengst Is Head of Sales

    Simcon’s Sales Team under New Management

    The manufacturer of the software solutions Cadmould and Varimos has a new sales manager since 1 June 2019.   more

  • Published on 05-20-2019

    Precise Simulation of Thermal Behavior

    Cooling Simulation with Temp-Flex Hoses

    Users can now precisely simulate and design the mold temperature control already at the planning phase.   more

    Simcon GmbH

  • Systematic Approach Pays Off
    Kunststoffe international 2017/09, PAGE 51 - 54

    Systematic Approach Pays Off

    Market Leader Brita Uses a Simulation Program from Simcon to Aid its Development Activities

    "Objectives are more readily attained by managing and steering activities and associated employees as a process." This is a statement taken...   more

  • Hidden Expertise
    Kunststoffe international 2015/04, PAGE 34 - 37

    Hidden Expertise

    The Sanitary and Heating Specialist Viega Uses Simcon Simulation Software in Development

    Viega, a leading manufacturer of installation technology, constructs over 100 new injection molds per year at its factory in Lennestadt,...   more

Company profile

Simcon GmbH

Schumanstr. 18a
DE 52146 Würselen
Tel.: 02405 64571-0
Fax: 02405 64571-20

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