Point made stands though, I think.
Because when you have a decent mold, the plastic will come out decent as well.
Where as most aluminum ones are made with a lathe.
Since I have not made reflectors I do not know if mostly are made on a lathe (why would anyone cast a reflector I do not know, since that would be opposite of lathe or CNC), but I know for sure if you ask a a serious manufacturer how they obtain the reflective surface is through vacuum plating (most even specify that), not actually uses tools to mirror polish it. The same vacuum plating specification you will find for plastics also, like in the reflectors for a car.
All alu’s could very well be casts, but spun to perfection on a lathe, then plated.
(Much less waste material)
Alu is extremely recyclable, so waste material is not a problem. These days everything is CNCed from rods, take the flashlight themselves, there is a lot of wasted material yet not one is casting pipes then machine thick pipes.
Plastic might last a long long time, it almost has a half-life, that does not mean it looks good as it ages, or doesnt become brittle etc. If I spend $200 on a light, it better outlast me. Maybe it wont turn on, but the parts better be capable of a rebuild/re-purposing like a 55 Chev.
Sure plastic is infinitely more moldable and light etc, but it has a shorter usefule life as it breaks down. Sur eit will still be around years to come, like all those old plastic bags etc. Still, they dont look like they did when new. Just because a better brand uses it, does not make it right. If we want to pull brand names out as if that means a lot in the argument, Hella still use glass and they use silver on glass for reflectors in the expensive items anyway. I dont know what they make the cheaper stuff from. Fenix is good, but it isnt Hella.
I think that's just it. Make that mold perfectly, and the plastic reflectors that come out of it should be very nearly identical. If you machine aluminum reflectors, each one is going to come out a little different. As Hikelite is saying, the finish might be the same quality since they'll both use aluminum vapor deposition, but there's only so much that can correct until it starts making things worse.
Aren't Maglite reflectors plastic too? I have a couple that are over 20 years old, and may be over 30 years old. Let me see if I can find them...
I doubt they'll have a problem. As I said, automotive oem reflectors are plastic too, and have been for generations. They've had plastic lens covers for the last 15 years, and we all know they suck, but we're talking about reflectors. There's little reason for the plastic reflectors to do worse than metal reflectors since it's the finish that matters. Old metal reflectors had problems with that too, which is what led to the current state of finishes created by a system that includes aluminum vapor deposition.
I don't know about vacuum plating, all the plastic I have seen plated, (seen the process), was regular plating in a bath, just like any other plating. I guess aluminum is different, but some of the aluminum must be regular dip plating, I see the marks on the back sides from the wires used to dip them and I see the brass coat applied under the chrome plate. Is that not dip coated?
Plastic automotive headlights use vapor deposition. I can't say for sure about flashlight reflectors, but I'd assume the same. I've seen one video that showed plastic flashlight reflectors undergoing aluminum vapor deposition, but I've tried and tried to find it again without success.
Here's the closest I can find, which doesn't add a lot.
This one is a little better.
Wait, I found it! Here's the one showing plastic reflectors. My memory was too good. It doesn't say this is used for flashlights. The image at the end makes me think it's for installation lighting.
I have plastic reflectors that are 30 years old and still in perfect condition. I don’t think plastic breaking down from getting old is an issue.