Originally Posted by
Jack G
Some of the supplier responses for this application are more than likely considering reproducing the lens using 3D printing methods which would be the least expensive approach. This process requires using 3D data files such as IGS, TIF, and others that define the object's geometry. However, the Crossfire lenses are made of polycarbonate (Lexan) material which may not be readily available in a raw material form suitable for 3D printing. For those not familiar with 3D printing systems these units are used in making prototype components using various types of polymer or plastic materials. My guess would be that the overall light transmission through a lens made with this method would be ranging from fair to poor. Obtaining a data file defining the Crossfire lens could also be a problem. This can be obtained by adding another step which would involve scanning the surface for data points, more$$$$.
3D printing would not work, the plastic has to be homogenous to get the clarity.
I think the best way to replace the lens is to cut off the front two dimension curved portion of plastic and replace it with a one dimension curved piece bonded to the old lens base. I think 1/8” thick PC sheet would be fine. The cut would follow the vertically aligned radius on the headlight and be done on a computer controlled machine.
The new plastic lens would be bent on a polished curved form in a heated oven, bending mainly under its own weight.
Addition force could be applied if required to the edges and any marks removed when adding a radii to the edges. The
radii could be added prior to bending if no extra force was required.