Making of the Combination Light Glasses

First the original form for the combination light glass was made by hand from a piece of plastic, with lots of sanding and polishing to high gloss. The lamp housings where made by 3D-printing, which would have been possible for the glass mold as well. Then a silicon mold was made, see the mold in the upper left in the picture. To make the production more economic the form was duplicated 8 times. After that it was could in half, to be able to make the combination lights in red/amber and clear/amber, see top left on the picture. With the duplicated parts the final silicon mold for production was made. This enables to produce 9 combination light glasses in one step.

Pic: Silicon molds for the combination light glasses

The clear resin was mixed with red or amber dye and de-gased in a vacuum chamber. But nevertheless small air bubbles could not be totally avoided in the glasses. This specific resin had to be cured in the oven for 1 hour. The glasses turned out milky if the mixing ratio was not perfect, and we had to start over again. Best practice is to mix substantially more resin as needed, because the mixing ratio can be determined more exactly for larger batches.

First the red or clear part was made in the small mold. The cured parts were then put in the larger mold and the amber part was made. Therefore almost all glasses have some amber resin on the other part which has to be removed by sanding and polishing. The lower right picture shows a glass directly from the mold in the upper left, and below the polished glass.

The combination lights for the PistenBully 400 are available at Pistenking.

Pic: Vacuum pump and vacuum chamber
Pic: Combination light glasses

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