Thermoformed PMMA Light Diffuser Cover

The task was to develop a transparent diffuser cover that would fit into an existing lighting housing after final trimming.

In addition to the required geometry, the part needed to retain transparency and clearly defined formed surfaces after thermoforming.

The first objective was a functional prototype, followed by a pilot run of 30 pieces once the geometry had been verified.

The part was developed around the requirements of the existing housing and the function of the transparent cover.

During design, the overall geometry, depth of the formed areas, radii, transitions and surfaces that would fit the existing product after final trimming were coordinated.

The geometry was adapted to vacuum forming transparent PMMA.

A dedicated tool using an epoxy-carbon system was manufactured for the project.

This type of tooling requires several technological stages, so tool preparation represented a significant part of the overall project lead time.

Once the tool had been completed, trial thermoforming was carried out to check geometry and forming in critical areas.

The diffuser cover was manufactured from 3 mm extruded PMMA (XT).

The material was vacuum formed over the prepared tooling so that it took on the defined geometry of the cover.

The result was a transparent technical vacuum-formed part intended for subsequent trimming and fitting into the existing lighting housing.

Following the trial part, a pilot run of 30 PMMA diffuser covers was manufactured.

TIM Infinity covered product development and design, tooling manufacture and thermoforming. Final trimming and fitting into the existing housing were carried out by the customer.

The phase of the project carried out by TIM Infinity was completed within 14 days.