目录
The process of sports sunglasses manufacturing involves more than just shaping lenses and frames. Every step — from material selection to assembly and quality testing — is designed to ensure safety, comfort, and durability. High-quality sports sunglasses not only enhance performance but also protect athletes from UV rays, glare, and impact. Let’s take a closer look at the key stages that make this possible.
I. Material Selection in Sports Sunglasses Manufacturing
In sports sunglasses manufacturing, the first and most critical step is choosing the right materials. The performance of the sunglasses depends on both the lens and the frame components.
- Lens Materials
Manufacturers often use polycarbonate or Trivex for lenses. These materials are lightweight, impact-resistant, and naturally block harmful UV rays. For example, polycarbonate lenses are up to 10 times stronger than standard plastic lenses and can withstand speeds of 160 km/h during impact tests.
To ensure UV protection, lenses are often coated or infused with UV400 filters, which block 99–100% of UVA and UVB rays.
- Frame Materials
Frames are usually made from nylon, TR90, or carbon fiber. These materials are flexible yet durable, allowing the sunglasses to maintain shape under extreme sports conditions. TR90 frames, for instance, can bend up to 20 degrees without breaking — a feature that’s perfect for cyclists or runners.
II. Lens Production and Coating Process
The next step in sports sunglasses manufacturing focuses on lens processing. This includes cutting, shaping, tinting, and coating — all of which affect performance and appearance.
（1）Cutting and Shaping
Manufacturers use CNC (Computer Numerical Control) machines to cut the lenses with micron-level accuracy. Precision is crucial because even a 0.2 mm deviation can affect how the sunglasses fit and block sunlight.
（2）Tinting and Polarization
Tinting determines how much light passes through the lens. For sports use, the Visible Light Transmission (VLT) usually ranges from 8% to 43%, depending on the sport and lighting conditions.
- Dark gray lenses: best for bright sunlight
- Brown or amber lenses: enhance contrast on uneven terrain
- Yellow lenses: ideal for low-light or cloudy days
Many sports sunglasses also include polarized lenses, which filter out horizontal glare from roads or water surfaces, reducing eye strain.
（3）Coating Technology
Modern sports sunglasses manufacturing uses multiple coatings to enhance function:
- Anti-scratch coating extends lens lifespan by 30–40%.
- Hydrophobic coating repels water and sweat.
- Mirror coating reflects intense sunlight, improving visibility during skiing or sailing.
III. Frame Molding and Assembly in Sports Sunglasses Manufacturing
Once lenses are ready, attention turns to frame creation and final assembly.
- Frame Molding
Most frames are made through injection molding, where molten nylon or TR90 material is injected into steel molds under pressures exceeding 1500 psi. This ensures consistent strength and shape.
Some high-end brands use 3D printing for prototyping and limited-edition designs, allowing for better ergonomic fitting.
- Assembly and Alignment
After molding, technicians align lenses and frames by hand or with robotic arms. Precision is essential — a 1° misalignment can distort vision or reduce UV protection. Hinges, nose pads, and rubber grips are then attached to improve comfort and stability.
IV. Testing and Quality Control in Sports Sunglasses Manufacturing
Before hitting the market, each pair of sunglasses must pass a series of strict tests.
- Optical and UV Testing
UV transmission is tested using spectrophotometers, ensuring full UV400 compliance. Lenses that allow more than 1% of UV rays above 400 nm are rejected.
- Impact and Stress Tests
Sunglasses must withstand high-speed impacts — typically tested using a 6.35 mm steel ball dropped from 1.3 meters. Frames are also stretched repeatedly to confirm flexibility and durability.
- Environmental Resistance
In advanced sports sunglasses manufacturing, lenses are exposed to 80°C heat and 95% humidity for 48 hours to simulate outdoor use. This ensures coatings and adhesives remain stable in real-world sports conditions.
V. Conclusion
From material selection to precision testing, sports sunglasses manufacturing involves multiple steps that balance science and craftsmanship. Each stage ensures that the final product not only looks stylish but also offers true protection and performance for athletes. When you wear a pair of high-quality sports sunglasses, you’re not just wearing fashion — you’re wearing years of innovation and engineering excellence.
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