Project background:

        Recently, a client with whom we work is working on the development of a new generation of in-vehicle lidar systems. They are facing challenges related to the tight timeline required for testing prototypes of the key components, as well as the high complexity of the manufacturing process. The design for the lidar components needed for L3+ level autonomous driving has just been finalized, and it is necessary to produce multiple prototypes of the housing structures and light-transmitting covers within 10 days, so that they can be used for optical testing, environmental testing, and assembly verification. Traditional molding methods take up to 45 days, and the cost per molding cycle is high, which makes it impossible to meet the demands of rapid product development. Given the tight deadlines and high technical requirements, the client turned to their existing suppliers right away, but all of them stated that they were unable to produce high-precision light-transmitting components within such a short time frame. Lidar light-transmitting covers require extremely high standards in terms of light transmittance, haze levels, and surface precision, and traditional manufacturing techniques cannot meet these requirements quickly. As a result, the client’s lidar development project was put on hold, with the risk of delays in the product release schedule.

Solutions and project outcomes

        To overcome the delivery challenges and ensure the customer’s research and development progress, the customer promptly reached out to the RPS team. Upon receiving the request, RPS quickly activated a dedicated R&D mechanism; it abandoned traditional molding methods and instead utilized specialized photosensitive resin 3D printing technology to meet the customer’s optical requirements, thereby accelerating the production process. The team worked round the clock to adjust the material formulas and printing parameters, enabling the precise creation of the complex curved optical structures required for the transparent covers. High-precision polishing and anti-reflective coating processes were also applied to ensure a light transmittance of over 92% and a haze level of less than 0.5%, satisfying all optical testing requirements.

        Thanks to its advanced material processing techniques and high efficiency, RPS was able to complete the development and delivery of three generations of products within 10 days, delivering a total of 24 prototype units. The dimensional accuracy of these units was maintained within ±0.05 mm, and they passed all vehicle-grade testing procedures, including optical tests, high and low temperature cycle tests, and vibration tests, on the first attempt. To minimize the time required for iterative improvements, the team assigned dedicated personnel to address the customer’s feedback, making adjustments and completing new prints on the same day, thus enabling rapid iteration within 24 hours.

        In the end, RPS helped the customer reduce the development and testing cycle for lidar systems by more than 70% and save over 80% in molding costs, ensuring that the customer’s products could proceed to the next stage of development as planned. This case highlights RPS’s technical expertise in optical-grade 3D printing as well as its ability to respond swiftly. With its professional and efficient services, RPS has provided strong support for the development of key components for autonomous driving, earning the customer’s high approval and interest in maintaining a long-term partnership.