Views: 0 Author: Site Editor Publish Time: 2026-03-18 Origin: Site
At Wincode Optronics we built the Phantom Aura 760XP around one key part: a brand-new single-piece PMMA lens.
This lens is much larger and thicker than most stage-light optics. It is nearly 1.5 times the diameter of the front lens cluster on an Ayrton Zonda 3FX and more than 30 mm thick.
The result is sharp narrow beams, smooth edge glow, and clean color mixing all from one fixture.
This lens is not easy to produce. Below we explain the real production process, the technical challenges we solved, and why this design gives the Phantom Aura 760XP its special performance.
PMMA, also called acrylic, is the most common material for stage-light optics. It lets through more than 92% of visible light and stays light in weight.
We use precision injection molding to make our lens.
First we dry PMMA pellets for 4 to 6 hours at 80 to 90 °C. Any water left in the material causes silver streaks or bubbles that destroy optical clarity.
Next the dry material heats to 220 to 260 °C. It then injects into a polished steel mold under high pressure.
The mold stays hot at 80 to 120 °C. This helps the plastic flow evenly and reduces stress marks.
After filling we apply high holding pressure for a long time. This packs extra material into thick areas to prevent sink marks or voids.
Cooling takes longer because the lens is thick. The part then ejects carefully to avoid scratches on the optical surfaces.
Hot runner systems keep the material molten so the large lens fills evenly without weld lines.
Our lens is much larger and thicker than typical stage-light optics. This creates several real difficulties.
The diameter is almost 1.5 times that of the Ayrton Zonda 3FX front cluster. At more than 30 mm thick the center cools much slower than the edges. This causes sink marks, warpage, and internal stress that bends light unevenly.
We must use high holding pressure for a long time to fill the thick center. This makes the cycle time much longer and lowers production efficiency.
The mold temperature must stay high to reduce flow marks and birefringence. But high heat makes the plastic stick to the mold. We need special mold coatings and precise cooling channels to solve this.
The mold design and mold investment cost are very high because of the large size and thick structure. We work together with large companies that have the right production capability. Small lens factories cannot make this lens.
Hot runner design is critical. Any temperature difference creates weld lines or uneven color. We use balanced manifolds to keep flow even.
Demolding is tricky. The large surface increases sticking risk. We use mirror-polished surfaces and gentle ejector systems to protect the optical finish.
At first the good-part rate was low. After many adjustments by skilled technicians we reached a higher yield and better efficiency.
We could have used several small lenses like many other brands. This is easier and cheaper.
We chose the single large lens because it gives three clear benefits.
First it creates extremely sharp imaging at narrow beam angles. Second it produces natural edge glow similar to high-end fixtures. Third it improves light transmission and color consistency across the whole fixture.
The large thick lens reduces light loss. It also helps the colors mix smoothly. Dimming stays flicker-free. These improvements let the Phantom Aura 760XP deliver three premium effects in one unit.
We worked with experienced factories because the lens makes the fixture stand out. It looks and performs like three high-end lights combined.
The Phantom Aura 760XP lens shows that advanced PMMA molding can solve real problems for lighting designers.
It is bigger, thicker, and harder to make than almost any other stage-light optic.
But the extra work gives sharper beams, richer edge glow, and better value.
Rental companies, theaters, and clubs get professional results without the usual high cost.
We are ready to share more details or samples with partners who want this kind of performance. Contact us to see what this lens can do for your shows.
