Transparent Polycarbonate Injection Moulding
The 7 Chakras Shower project combines optical-grade polycarbonate injection with integrated LED lighting systems. Each shower head is moulded in a single shot using Makrolon polycarbonate, achieving crystal-clear transparency while maintaining the mechanical strength required for daily use in wet environments.
Our high-precision moulds ensure wall thickness uniformity of ±0.1mm across the entire part, critical for even light diffusion. The internal geometry channels water while housing the LED system, requiring complex core design with multiple lifters and slides.
Material: Optical-Grade Polycarbonate
Makrolon (Covestro) polycarbonate was selected for its exceptional optical clarity (92% light transmission), high impact resistance (notched Izod: 12-17 kJ/m²), and heat deflection temperature of 130°C. Unlike PMMA, polycarbonate withstands the thermal cycling inherent to shower use without cracking or yellowing.
The material meets EU drinking water contact regulations and carries NSF certification. UV stabilizers are added to the compound to prevent long-term discolouration from bathroom lighting.
Manufacturing Process
Injection parameters are precisely controlled: melt temperature 290-310°C, mould temperature 90-110°C, injection speed profiled to prevent flow marks on optical surfaces. A hot runner system with valve gates eliminates vestige marks on visible surfaces.
Post-moulding, each part undergoes an annealing cycle to relieve internal stresses that could cause birefringence. 100% visual inspection under polarized light ensures optical quality meets specification.
LED Integration & Assembly
The shower head design incorporates snap-fit features for the LED module, eliminating adhesives. IP67-rated sealing grooves are moulded into the body. The chromotherapy system cycles through 7 colours, each associated with a chakra, powered by a self-contained turbine generator activated by water flow.
Quality Assurance
ISO 9001:2015 certified production. Every batch undergoes pressure testing (10 bar), flow rate verification, LED function testing, and accelerated ageing (1000 hours UV + humidity). Dimensional inspection via CMM ensures interchangeability across production runs.
Applications
Originally developed for the wellness and spa market, this design has expanded to luxury hospitality (5-star hotels), residential bathroom renovation, and therapeutic applications. The chromotherapy function provides measurable relaxation benefits documented in clinical studies.
Frequently Asked Questions
What is the minimum order quantity for custom shower heads?
We offer pilot runs from 500 pieces for market testing, with production series from 5,000 units. Mould amortization is included in the per-unit price for orders above 10,000 pieces.
Can the design be adapted for different LED configurations?
Yes, the mould incorporates interchangeable inserts for the LED housing area. We can accommodate single-colour, multi-colour, or temperature-responsive LED systems within the same base mould.
What is the lead time for a similar project?
Mould fabrication takes 5-6 weeks. First samples are available within 7 weeks of design approval. Full production ramp-up within 8-9 weeks.
Technical Specifications
Material: Makrolon 2858 PC | Wall thickness: 2.0-3.0mm | Weight: 185g | Mould: 2-cavity, hot runner | Cycle time: 42s | Annual capacity: 150,000 units | Certifications: ACS, NSF 61, CE