Maya Ellison
Tail lights are typically made from a blend of polycarbonate and acrylonitrile-butadiene-styrene (PC/ABS). This blend results in a moulded part with excellent clarity and light transmission, as well as improved impact and temperature resistance. Polycarbonate (PC) and acrylic (poly methyl methacrylate, or PMMA) are two distinct materials, but both can be glued with solvents such as methylene chloride. Tail lights are vulnerable to the sun's UV rays and can become foggy and discoloured over time.
| Characteristics | Values |
|---|---|
| Material | Polycarbonate and acrylonitrile-butadiene-styrene (ABS) blend, red acrylic, plexiglass, or PVC |
| Texture | Smooth or textured for light dispersion |
| Fabrication method | Vacuum forming, injection molding, or machining |
| Suppliers | Plastics shops, online merchants |
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What You'll Learn
Tail lights are made from a blend of polycarbonate and acrylonitrile-butadiene-styrene
Tail lights are typically made from a blend of polycarbonate and acrylonitrile-butadiene-styrene, commonly referred to as PC/ABS. This blend is ideal for tail lights due to its superior optical and mechanical properties.
Polycarbonate (PC) is a tough, durable plastic with high impact resistance and excellent light transmission qualities. It is a popular choice for automotive applications as it can withstand the rigours of the road and provide long-lasting performance. Acrylonitrile-butadiene-styrene (ABS) is another strong and versatile plastic that enhances the impact resistance and temperature stability of the polycarbonate.
When combined, PC and ABS create a material that is ideal for tail lights. The blend results in moulded parts with outstanding clarity and light transmission, ensuring that the tail lights illuminate effectively. Additionally, the blend offers enhanced impact and temperature resistance, making it suitable for the varying conditions that vehicles encounter.
The process of fabricating plastic tail lights often involves creating a mould and using techniques like vacuum forming or injection moulding to shape the plastic. Some enthusiasts even experiment with customising their tail lights by using plastic sheets, tinting, or creating unique textures for light dispersion.
In the past, companies like Ford used large plastic lenses on the tailgates of their trucks, and these have served as a source for custom lens creations. Today, with advancements in materials and fabrication techniques, tail lights made from PC/ABS blends offer optimal performance, durability, and aesthetics for vehicles.
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Polycarbonate plastic is used for tail light lenses
Polycarbonate is a strong, impact-resistant plastic used for manufacturing tail light lenses. Its transparency and ability to withstand impacts make it a durable option for tail lights. Polycarbonate lenses can withstand harsh conditions and maintain their clarity, making them a popular choice for various vehicles.
One of the key advantages of using polycarbonate plastic for tail light lenses is its high tensile strength and impact resistance. This means that polycarbonate lenses won't break easily in the event of an accident, providing enhanced safety for drivers and pedestrians alike. Additionally, polycarbonate has a higher temperature resistance compared to other plastics, such as acrylic, which can only withstand temperatures up to 190° F before softening. Polycarbonate can resist temperatures up to 240° F, making it a more suitable choice for tail light lenses that need to withstand extreme conditions.
Another benefit of polycarbonate plastic for tail light lenses is its ease of fabrication and customization. Unlike acrylic, which requires heating to be bent, polycarbonate is more flexible and can be moulded into complex shapes without the need for additional heat. This makes the manufacturing process more efficient and cost-effective, as polycarbonate lenses can be produced using injection moulding techniques.
While polycarbonate offers superior impact resistance and temperature tolerance, it is important to consider its drawbacks. One of the main disadvantages of polycarbonate lenses is their tendency to oxidize over time. This oxidation can result in hazy, yellowed headlights, reducing illumination for the driver and impacting visibility for other road users. Additionally, polycarbonate has a slightly lower light transmittance than acrylic, with 88% light transmittance compared to acrylic's 92%.
Despite these drawbacks, polycarbonate plastic remains a popular choice for tail light lenses due to its strength, durability, and ease of fabrication. Its impact resistance and temperature tolerance make it a safer option for vehicles, and its ability to maintain clarity under harsh conditions ensures optimal performance over time. For those seeking an alternative, acrylic is also used for tail light lenses, offering higher light transmittance and lower cost but with lower impact resistance and temperature tolerance.
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Tail lights can be made using plexiglass
Tail lights are typically made from a blend of polycarbonate and acrylonitrile-butadiene-styrene, which offers excellent clarity, light transmission, and impact and temperature resistance. However, it is possible to make tail lights using plexiglass, also known as acrylic glass. Plexiglass is a versatile plastic that can be easily cut, moulded, and drilled, making it suitable for custom tail light fabrication.
Plexiglass is often used as a protective cover for fluorescent lighting fixtures, and its light transmission properties make it a viable option for tail light lenses. When combined with a red tint or coating, plexiglass can effectively transmit light while providing the distinctive red colour typically associated with tail lights.
One advantage of using plexiglass for tail lights is its durability and impact resistance. Plexiglass is known for its toughness and can withstand minor bumps and scratches without shattering or cracking. This makes it a suitable material for automotive applications, where durability and impact resistance are crucial.
Additionally, plexiglass is relatively easy to work with, especially when compared to other types of glass or plastic. It can be cut, drilled, and shaped using standard workshop tools, making it accessible to hobbyists and professionals alike. This ease of fabrication allows for custom tail light designs and one-off creations.
However, it is important to note that tail lights made from plexiglass may not meet all the legal requirements for road use. In many jurisdictions, tail lights must be approved by regulatory bodies, such as the DOT in the United States, to ensure they meet specific standards for brightness, colour, and durability. While plexiglass can provide adequate light transmission and durability, using non-approved materials may result in legal repercussions or safety concerns.
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Tail lights can be fabricated using vacuum forming
Tail lights are an essential component of automobiles, providing vital visibility and communication with other drivers. The fabrication of these lights involves a range of processes, with vacuum forming being one of the key techniques.
Vacuum forming is a manufacturing process that can be leveraged to create tail light lenses. This method involves using a vacuum to draw molten material into a mould, resulting in a precise replication of the prototype. While it is a more expensive process, it offers flexibility and is suitable for low-volume production. Tail light lenses can be crafted using this technique, ensuring both structural integrity and aesthetic appeal.
The materials used in vacuum forming for tail lights are crucial. Polycarbonate plastic is a common choice for lenses due to its impact resistance and temperature resilience. Additionally, PMMA (polymethyl methacrylate), also known as Perspex or Plexiglass, is a transparent resin that can be tinted to create the distinctive red or orange colours often seen in tail lights.
To enhance the functionality of tail lights, manufacturers may employ techniques like sublimating aluminium or silver in high-vacuum chambers to create reflectors. This intensifies the LED emission, resulting in a more uniform light area. Furthermore, surface finishing treatments are applied to tail lights to enhance their appearance and functionality, ensuring sharp edges are removed and the lenses are clear.
Vacuum forming is just one of the processes used in the fabrication of tail lights. Injection moulding, CNC machining, and rapid injection moulding are also employed, each offering unique advantages. Ultimately, the creation of tail lights involves a combination of these processes, ensuring the final product meets the required standards of quality and performance.
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Injection moulding is another way to make tail lights
Once the mould is created, the tail light can be cast from acrylic or Poly Methyl MethAcrylate (PMMA). PMMA is the resin used for most original equipment tail light lenses and is known for its clarity and transparency. It can be purchased under the trade names "Perspex" or "Plexiglass". Colours can be added to the resin, but multi-colour lenses must be cast in individual colour pieces. Alternatively, the lenses can be painted on the inside with a transparent tint.
Polycarbonate plastic is also recommended for the lenses. This plastic is known for its outstanding clarity and light transmission qualities, as well as its enhanced impact and temperature resistance. This type of plastic is often blended with acrylonitrile-butadiene-styrene (ABS) to create a material blend with improved characteristics.
Injection moulding is not a cheap process, and the cost of creating a mould can be significant. However, there are ways to reduce costs, such as using a 3-shot injection moulding process with three colours (bright red, dark red, and transparent) and three separate moulds. This setup allows for cost savings by avoiding the use of a more expensive rational mould.
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Frequently asked questions
Polycarbonate, the same plastic used in headlights.
Polycarbonate (PC) is a blend of polymers that results in enhanced impact and temperature resistance.
Polycarbonate is often blended with acrylonitrile-butadiene-styrene (ABS) to make tail lights.
Acrylonitrile-butadiene-styrene (ABS) is a type of polymer in the same family as PVC.
Yes, you can use methylene chloride as a solvent to glue these plastics together. However, this substance is considered carcinogenic and may be banned in some areas.
