Automotive lamp Mold Design and manufacturing Solution
Mold for automotive lighting
For cars, lamps are an indispensable feature. No matter whether it is a traditional or technologically-stylish model, the most important parts of the lamp are headlight body, reflector, decorative frame and lamp lens. As the automotive exterior parts in highest demand, the design and manufacturing requirements for mold for automotive lighting are also very high.
The first challenge comes from the headlight body.
Being an internal functional part, the appearance requirements are not very high. However, there are lots of holes and clips used for assembly, which means there may be risks in the design and manufacturing of mold for automotive lighting:
1. Too many lifters, slides, and inserts in the mold, which could cause mismatch and flash easily for the mold for automotive lighting.
2. Difficulties regarding mold cooling and conduct complex cooling system;
3. Increase in individual electrodes and proceed amounts of EDM.
Secondly, for the decorative frame of mold for automotive lighting, attention should be paid at the mold design stage to accomplish high surface requirements.
This is a decorative function part of the headlight lighting system that is located inside, assembled with the lens, and can be seen from the outside of the headlight through the lens. Generally, the manufacturing materials of the decorative frame of a car lamp are PC / PBT + GF / PBT + PET / PA + GF, and the part requires surface plating.
For this purpose, Root sino experience is to select high-quality mold steel while paying attention to the points below:
1. The position of the gate and the welding line must be accurately designed by previous mold flow analysis;
2. The cavity must be designed to prevent part sticking;
3. The cooling system and the ejector system must be designed to prevent deformation of the mold for automotive lighting.
4. Pay attention to the depth of the texture to prevent flow marks.
In order to achieve the manufacturing requirements of mold for automotive lighting with strict light distribution and directly aluminum-plated, Root sino recommends paying attention on the following points during the mold for automotive lighting design:
1. Avoid clearance at PL surface of the mold, to reduce the risk of flashes;
2. Mold flow analysis for good design of gate position and the welding line;
3. The layout of the heater of the cavity and core must be reasonable to prevent deformation;
4. Add ejector bush to prevent the ejectors burning out by high temperature;
5. The surface texture contour requires high accuracy;
6. Aim to keep the mold core as a whole, to avoid flashes inside of part.
In conclusion, based on the above product requirements and mold characteristics, Root sino has a complete solution from raw mold steel to mold for automotive lighting delivery: The material selections are all from professional automotive mold steel manufacturers such as SCHMOLZ+BICKENBACH in Germany, Datong in Japan and AssAB in Sweden.
