A highly efficient regular curved retroreflector is proposed to meet the requirements of the US Society of Automotive Engineers (SAE) regulations. It is demonstrated that 28% higher retroreflection efficiency and 33% more working area can be accomplished with the new designed retroreflector when compared with the commercial ones used in modern vehicles.Based on pin-bundling technology, the tooling of a reflex reflector mold can be produced, and it can serve as a testing sample or for mass production. In this study, a reflex reflector sample was designed and produced by bundled metal pins for SAE regulations. A curved retroreflector with new cube-corner structure is proposed and demonstrated. By use of genetic algorithms for optimization, the angles and positions of the pins serve as the optimizing parameters to enhance the performance of a curved retroreflector. Compared with conventional retroreflectors, it is found that 28% higher retroreflection efficiency and 33% more working area can be accomplished with our proposed one. effective working area and reflection efficiency are influenced seriously, and that could lead to the retroreflector not complying with SAE regulations [6,16].Based on pin-bundling technology, the tooling of a reflex reflector mold can be produced, and it can serve as a testing sample or for mass production. In this study, a reflex reflector sample was designed and produced by bundled metal pins for SAE regulations. A curved retroreflector with new cube-corner structure is proposed and demonstrated. By use of genetic algorithms for optimization, the angles and positions of the pins serve as the optimizing parameters to enhance the performance of a curved retroreflector. Compared with conventional retroreflectors, it is found that 28% higher retroreflection efficiency and 33% more working area can be accomplished with our proposed one.