15 Years of Deep Cultivation And Customized Optical Cores

       - A full Analysis Of The Optical Lens Intelligent Manufacturing Factory Of Shenzhen Sunshine Technology Co., Ltd.

In the industrial map of Shenzhen manufacturing, there is such a company: it has been rooted in the field of optical lenses for 15 years, from an earlymold processing factory to a national high-tech enterprise integrating optical design, mold development, and precision manufacturing. When the industrial waves of LED lighting, smart terminals, and automotive optics swept the world, Sunshineopto always took "precision customization" as the core, using more than 40 injection molding equipment for 24-hour production, a commitment to a 25-day ultra-fast delivery period, and 100% full inspection. Strict, writing the legend of ingenuity of China's optical intelligent manufacturing.

1. Customized gene: full-link empowerment from optical design to mold development

As one of the few intelligent manufacturing factories in the industry that provides free optical design services, Sunshineopto's technical team always believes that every lens is a container of light, carrying the customer's unique imagination of light and shadow. When customers visit with vague product concepts, engineers will start the "demand decoding" process within 24 hours - use the optical simulation software LightTools to simulate the optical path, and combine the molding capacity of the 60T-600T injection molding machine to provide more than 3 sets of optical solutions for customers to choose from. A new energy vehicle customer once raised the problem that "the lens of the on-board atmosphere light needs to achieve 180° uniform light distribution". The technical team achieved an anti-glare effect of UGR<19 through aspheric design combined with microstructure processing, and finally helped the customer's product pass the automotive industry certification.  

In the mold development stage, the precision processing unit composed of 5 mirror spark machines and 5 high-speed engraving machines is performing the magic of "from drawings to real objects". The factory's original three-level mold verification system: integrating sphere optical test after the initial sample trial, precision detection (error control within ±0.01mm), and customer scenario simulation test to ensure that the optical performance and structural strength of each mold meet the standards. Data shows that the factory's mold one-time pass rate reached 92%, far higher than the industry average of 75%.

2. Smart manufacturing strength: flexible production matrix constructed by 40 injection molding machines

Walking into the 1,500㎡ intelligent production workshop, 4 automated production lines are operating in an orderly manner: 60T injection molding machines specialize in micro lenses with a diameter of less than 20mm (such as IR infrared lenses), and 600T large equipment is good at molding street lamp lenses above 200mm. More than ten manipulators accurately grasp workpieces to minimize manual intervention. This layout of "matching large and small equipment and complementing fast and slow production capacity" allows the factory to undertake both sample orders of 5,000 pieces and batch orders of 500,000 pieces.

Quality control runs through the entire production process: each injection molding machine is equipped with an independent mold temperature control system (accuracy ±1℃) to ensure the stability of the material melting state; 3 Yuanfang photoelectric integrating sphere testers conduct triple detection of light efficiency, color temperature and uniformity for each batch of products; from the RoHS certification review of raw materials entering the warehouse to the drop test (simulating transportation vibration) of finished products leaving the warehouse, 12 quality checkpoints weave a strict quality control network. The 2023 customer satisfaction survey shows that the product delivery qualification rate reached 99.8%, and the return and exchange rate was only 0.2%.

3. Extreme response chain: the process revolution behind the 25-day delivery period

Under the nourishment of Shenzhen speed, SUNSHINEOPTO has created an industry-leading "three-stage nine-step" delivery system:

Design stage (0-7 days): demand docking → scheme design → drawing confirmation

Mold stage (8-15 days): steel procurement → precision machining → initial sample testing

Production stage (16-25 days): raw material preparation → injection molding → full inspection and packaging

This ability to compress the traditional 45-day cycle to 25 days comes from three major efficiency innovations:

① Strategic reserve of mold steel (commonly used NAK80 and S136H steel are always available at 50 tons),

② Order intelligent scheduling system (real-time monitoring of equipment load rate),

③ Cross-border logistics front-end layout (establishing a 24-hour response mechanism with freight forwarders).

The factory adjusted spare molds and started three-shift production, and finally completed the entire process from mold opening to delivery within 18 days, setting a new industry delivery record.

4. Value extension: an optical lens partner that goes beyond manufacturing.

While peers are still competing in equipment scale, Sunshineopto has extended its service tentacles to the upstream and downstream of the industrial chain: providing design-proofing-small batch trial production nanny-style services for start-ups, helping customers shorten product development cycles by 40%; providing mold hosting services for listed companies, through regular maintenance and performance upgrades, the mold life is extended by more than 30%; and launching a "double-clearance tax package" logistics solution for overseas customers to solve the last mile problem of cross-border trade.

In the field of lighting applications, the factory customized a high CRI (Ra≥95) lens for a European lighting brand, helping its products pass the ROHS ,CE certification; in the field of consumer electronics, the lens developed for a domestic head flashlight manufacturer reduced the thickness of the terminal product by 30%; in the field of automotive optics, the adaptive headlight lens cooperated with a new energy vehicle company successfully passed the CE LVD certification. These successful cases across different fields confirm Sunshineopto's service philosophy of "defining products based on customer needs."

5. Future Vision: Secondary Transition from Manufacturing to Intelligent Manufacturing

Standing at the new starting point of the 15th anniversary, the factory is launching an intelligent upgrade plan: introducing an AI optical design system to increase solution generation efficiency by 50%; deploying an MES manufacturing execution system to achieve real-time traceability of production data; and preparing to build a CNAS certified laboratory to provide customers with more authoritative optical lens testing services. As the general manager said in his anniversary speech: "We are not porters of standardized products, but engineers of light and shadow art. When each lens carries the customer's innovative dream, our value lies in making the dream shine into reality."

From the factory in Shenzhen to customer sites in 32 countries around the world, Sunshineopto always believes that in the field of optical lenses, which is a field where precision manufacturing and creative design are intertwined, only by deepening technology, being close to customers, and respecting quality can we gain a firm foothold in the wave of industrial change. If you are looking for a partner who understands optics, manufacturing, and your needs, Sunshineopto has 40 injection molding machines are ready, the promise of a 25-day delivery period is always online, and 15 years of industry accumulation is waiting for your inspection.

Let us use light as a medium to jointly create the infinite possibilities of the optical industry !

From Shenzhen Sunshine Opto-Electronics Technology Co., Ltd.,

Tel/whatsapp: 0086-13510560547

 Website: www.sunshineopto.com