DYPE | An automotive lamp reflector coating solution integrating PVD and PECVD in one chamber

Three processes in one cycle | Replacing the conventional "spray → aluminize → spray" flow

Automotive lamp reflectors and bezels demand high reflectance, consistent appearance and long-term weather resistance. In the conventional vacuum metallization process, parts are spray-primed, loaded into a vacuum chamber for aluminizing, then removed and spray top-coated. Moving parts back and forth between the spray line and the vacuum chamber not only lowers yield through dust and paint runs, but also brings heavy solvent emissions, paint waste and energy consumption.

The Dah Young Vacuum DYPE Hybrid Coating Machine integrates PVD thermal evaporation and PECVD (plasma-enhanced chemical vapor deposition) in the same vacuum chamber. After the aluminum reflective film is deposited, a transparent protective film is formed directly by plasma polymerization without breaking vacuum, so the metal film never contacts air or leaves the chamber. This greatly reduces spray paint usage and environmental pollution while improving production yield and efficiency, in line with global automakers' green manufacturing trends.

Semi process and full process | Flexible adoption based on product conditions

DYPE offers two process modes, and customers can choose how to adopt them based on substrate, existing production lines and quality requirements:
● Semi process (Semi-DYPE): Keeps the existing base coat spraying, while the aluminum reflective film and PECVD protective top coat are completed in the chamber. Top-coat spraying and curing are eliminated, raising yield and lowering pollution and energy use.
● Full process (Full DYPE): Base coat, aluminum reflective film and top coat are all completed inside the vacuum chamber with no spray line, achieving a complete green process with high yield, low pollution, energy savings and resource efficiency.

Meets automotive reflector test requirements | High reflectance, water resistant, corrosion resistant, no yellowing

The aluminum reflective film deposited by DYPE, combined with the PECVD protective film, achieves reflectance of approximately 85 ~ 90% in the visible range (400 ~ 800 nm) and passes common reliability tests for automotive reflector coatings:
● Water resistance: 40°C immersion for 30 hours (ASTM D870), pass.
● Adhesion: Cross-cut tape test (ASTM D3359), pass.
● Corrosion resistance: 1% KOH solution for 10 minutes, pass.
● Appearance: No haze, yellowing or iridescence.

Planetary rotation × 1500 mm long axes | Uniform coverage of 3D reflective surfaces

Lamp reflectors are mostly deep concave surfaces with ribs and mounting features, where film thickness tends to vary in recesses and at edges. DYPE 1300 / 1600 / 1800 use vertical planetary fixtures that revolve and rotate every part, with an effective length of 1500 mm per axis. Whether parts are placed at the top, middle or bottom of the fixture, they achieve consistent film thickness and adhesion. Large batch loading makes them well suited to mass production.

High-efficiency pumping × cryogenic water vapor capture | One batch every 18 ~ 20 minutes

Plastic substrates and base coats continuously release water vapor in vacuum, a key factor in pump-down time and film quality. DYPE combines an oil-sealed rotary pump, Roots booster, diffusion pump and holding pump into a complete pumping system with a cryogenic water vapor pump. A new, clean, empty chamber at room temperature reaches 2.0 × 10⁻⁴ Torr from atmosphere within 5 minutes, with an ultimate vacuum better than 5 × 10⁻⁶ Torr. The overall cycle time is approximately 18 ~ 20 minutes per batch, effectively increasing equipment turnover.

Five chamber sizes | From large single parts and mainstream production to elongated lamps

The DYPE series offers five chamber sizes covering different part sizes and capacity needs:
● DYPE 1000: Single-axis large fixture with an effective coating diameter of Ø700 mm, suited to large single parts and high-mix, low-volume production.
● DYPE 1300 / 1600 / 1800: 6 / 8-axis planetary rotation; the mainstream production models for lamp reflectors and bezels.
● DYPE 2000: Elongated chamber (2000 mm inner width) with 2-axis rotation for large, elongated lamp parts such as full-width rear lamps.

Total solution | One-stop integration from molding to coating

Dah Young Vacuum can integrate injection molding, spray painting and curing, vacuum coating equipment, coating consumables, vacuum pumps and cryogenic capture systems to help customers plan complete lamp coating lines. We also provide regular inspections, remote connection service, production parameter and product adjustment recommendations, equipment operation training and problem analysis, keeping equipment running stably in long-term production.