TESTING

Quality control system for engineered transparent components

From material receipt to delivery: every stage of the production cycle is subject to defined, documented and traceable quality controls

LIRAS Optical manages the quality of transparent components through a structured system covering the entire production cycle: from incoming material inspection to final testing and delivery documentation. Inspections are not concentrated at a single point; they are distributed throughout every stage of production so that any non-conformity is detected as close as possible to its source.

STAGES

Stages of the inspection and testing process

The system is based on documented inspection specifications, process operating instructions and Product Quality Plans (PQPs) defined by component type and industry.

Incoming material inspection

Every batch of raw material - polycarbonate, PMMA, resins and screen-printing inks - is inspected on receipt and recorded under a traceable batch number. The inspection includes a visual appearance check, verification of thickness against the technical data sheet and recording of the batch label. Non-conforming material is excluded from the production cycle.

Optical inspection: visual quality and dioptric power measurement

Optical inspection is the most critical verification for an engineered transparent component. LIRAS Optical measures dioptric power - the component's potential to distort light - in specific areas and at different viewing angles.

The method used - the oblique-stripe screen method, SCG 003 - verifies distortion in optically critical areas, with different tolerances for each zone and measurement angle. Derived from automotive and aviation standards for safety glazing, this inspection ensures that the component does not introduce visual distortion that could impair the driver's or pilot's perception.

Optical inspection is performed both after forming and during final testing to detect any changes introduced by subsequent processing stages.

Dimensional inspection

Geometric conformity is verified against the customer drawing by checking curvature, perimeter dimensions and thickness. The standard thickness tolerance is ±0.3 mm unless otherwise specified by the project. Inspections are performed using identified and registered instruments with traceable calibration status and due dates.

Surface treatment inspection

Hard coating and screen printing undergo specific adhesion tests (SCG 002) for each application batch. The batch numbers of the hard-coat resin and screen-printing ink are recorded, together with the thermal curing cycle applied. The adhesion test verifies that the treatment is permanent and complies with the relevant specifications.

For components fitted with a micro-wire heating system, a functional test of the resistive system (SCG 006) verifies electrical continuity and heat distribution across the finished component.

Material and process traceability

Every component is accompanied by a manufacturing route card that records, stage by stage, the raw material batch, process parameters (temperatures, times and cycles), the results of every intermediate inspection, treatment material batches and the signatures of the responsible operators. Traceability is complete from raw material to the delivered component.

Final testing

Before delivery, every component undergoes final testing comprising a visual appearance inspection, dimensional and curvature checks, optical inspection with zone-specific dioptric power measurement, screen-printing inspection (transparency, marking and dimensions), thickness verification and confirmation that the packaging complies with project specifications. The component is declared conforming or non-conforming, with the responsible operator's signature and date.

Documentation, warranty and operating instructions

Every delivery is accompanied by operating and maintenance instructions (DOC 117), defining the correct procedures for handling, installation, cleaning and storage, as well as the component's chemical compatibility. Failure to follow these instructions may compromise product performance and invalidate the warranty.

The warranty covers verified manufacturing defects for 12 months from the delivery date. Claims must be submitted in writing within eight days of discovering the defect.

Applicable certifications and standards - including ECE R43, ISO 6055 and ISO 3449 FOPS Level II for the relevant sectors - are specified in the documentation for the individual component and project rather than stated generically.

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