Automotive Headlight Mockup - INAC, Inc.

Headlight mock-up

HEADLIGHT

HEADLIGHT ASSEMBLY MOCK-UP

High-Quality Headlight Mockups: From Lens to Housing

This project demonstrates a fully assembled headlight mockup, manufactured completely in-house. We combine advanced technologies to achieve crystal-clear appearance and realistic reflectivity, making these prototypes ideal for design verification and exhibitions.

Key Technologies:

Clear Parts: Polycarbonate/acrylic machining and transparent SLA 3D printing for lenses and light guides.

Surface Finishing: Professional polishing to achieve glass-like transparency.

Reflectors: Aluminum evaporation (vacuum metallizing) for high-reflectance mirror finishes.

Assembly: Complete integration of all components including painting and housing.

We deliver production-grade mockups with short lead times to meet your development schedule.

Please feel free to contact us.

Adequate support will be provided by our experienced designers until prototype completion.

Exploded view of components

SLA + vacuum casting​

SLA + vacuum casting

Chemical wood machining + painting

Chemical wood machining + painting

SLA + painting​

SLA + painting

Aluminum evaporation / acrylic​

Aluminum evaporation / acrylic

Diagram of components

Diagram of components

Finished product​

Finished product

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STEP5: Quality Assurance and Precision Inspection

A quality inspection is performed. At INAC, where quality comes first, we use CMMs, gauges, and other equipment for precision checks.

STEP4: Post-Processing and Finishing

Finishing is done by removing the supports, polishing, and applying transparency treatment. It is also possible to paint and apply plating to the formed product.

STEP3: UV-Laser Print Formation (SLA Process)

Output: The product is formed by irradiating the liquid with a laser beam of UV light and laminating it. The conditions of the external environment, such as room temperature and humidity, must be maintained.

STEP2: Model Program Generation and Support Adjustment

A program for model formation is created. Depending on the shape, it may be necessary to adjust the degree of tilt and the position of the supports.

STEP1: CAD File Submission

Upload your CAD to our online quoting platform.

STEP 3: Rendering and Scene Integration

We can also handle exterior modeling and interior structure design based on illustrations. After creating the 3D models, we can create a rendering to fit a scene. We can deliver images even if we do not proceed with production.

STEP 2: Detailed Design and 3D Modeling

Once the design is determined, drawings and 3D models will be created. The structure will be examined, taking into consideration not only the external design but also functionalities such as mating and sliding.

STEP 1: Initial Design Consultation

The first step is a meeting to discuss the project. Drawings are not required for this meeting. We will create a design from a sketch based on the overall image and concept that you have in mind.

STEP5: Quality Assurance and Inspection

We perform quality inspections. At INAC, where quality comes first, we use CMMs, gauges, and other equipment for precision checks.

STEP4: Post-Casting Finishing

Vacuum casting materials are cured and then taken out of the silicone rubber mold. Then we perform finishing such as deburring and gating, and they are made into finish products.

STEP3:Material Injuction

Liquid casting material is injected into the silicone rubber mold in a vacuum environment.　

STEP2: Mold Preparation

The silicone mold is cut open into a male and female mold, and the master model is removed.

STEP1: Mold Creation

The master model is fixed to a wooden frame and silicone is poured to create a mold.