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Auto head / side turn / tail lamp mold
Auto head lamp Mold
Auto side trun lamp mold
Auto tail lamp mold
The major aspects of the auto lamps are plastic components, which are made through mold machining and injection production. The most important element is mould. Following are some opinions about three most important components of plastic lamp project- LENS, BESEL, HOUSING. Instructions for Designing and Machining of LENS Mold For the LENS part, the most important thing is high degree transparency, clear split line and product with minimum distortion, making sure the surface and optical performance. When designing the mould, mould splitting should be strictly following the split line of supplied 3D data, inner and outer sliders should be in accordance, avoiding to use ejector pins on the part, even by applying ejector block, minimum split line should be seen on the part surface. Only one gate is allowed, and it should be located on the middle edge of the length side, to keep the flowing balance, and the moldflow is nesseccery. Sufficient and fairly cooling should also be considered. I suggest to use 8407 or 136 from ASSAB Sweden for core and cavity and slider steel, the hardness should be HRC48 to 52 after heat treatment, to prevent scratching on the polished mirror surface during production. After mold rough machining and hardening, it is suggested to processed with 5-Axis Machining Center to complete the plastic planes processing of a whole part to avoid errors caused by repeated clamp on machine and insuring the optical properties and smoothness of the part without deformation. Mold should be polished by professional polishing factory to avoid any slight deformation of the mold surface.
The difference between bezel and lens is the transparency of the lens, while bezel is opaque which is used to reflect light. It is important to insure the direction of the reflected light is consistent, both the front side and reflective side require high polish while surface of core surface is of common requirement. In this case, the designing should focus on plastic bits and reflective area. Especially for the reflective area, it requires sufficient cooling. When checking the product, pay attention to evenness of the reflective area and no ribs at the back side, that is to avoid the unsmooth appearance caused by uneven thickness of plastic or slight shrinkage thereby affecting the optical properties. Some Bezel has oblique led light rib, the mould core could be designed into float core structure. Make mold-flow to check the weld-line.
The difference between housing and the former two parts is as follows: lens and bezel are exterior parts, while housing is a interior structure part for assembling other components, mainly in maintaining its assembly function, especially at the position of bulb. The most important point is insuring assembly dimensions of the whole product. Pay attention to the shape and size related with assembly when designing the mould, considering some dimensions might be adjusted in future, inserts may be a good choice for a convenient mould adjustment after T0. Cooling of inner side of the mould shall be adequate as housing is a box-shaped part, berylium copper insert is recommended at some area with deep cavities if necessary, to insure production cycle time, meanwhile, help to reduce deformation of the product to realize correct dimensions. Economic pre-harden steel is optional when choosing steel to shorten the lead time of mould making, you can also make inserts at the important shut off surface. Requirements on processing and polishing for HOUSING mould is common.
Injection system design should be thick and short, with cold slag well. Side gate and fan gate are preferred by large section, but to avoid over stress around the gate. Or direct valve gate to top of part.
Cavity slide, Inserts, Core slide, Lifters, Ejection bars, to release the undercut.
Considering special requirement of auto lighting part, any poor venting could badly influence part appearance quality with black spot and transparency.
Mold temperature and even cooling will directly influence the even transparency effect of final part
cooling space should be strictly under control, Avoid pool type cooling as much as possible.
Double angled cooling shall be used to keep even cooling in cavity &core when necessary
No mark permitted on non assembly surface, including ejection mark because of transparency and appearance property of Lens.
Coiling ejection is used on this kind of part. All the ejection mark is in the matching components assembling range, without effect on the part visible surface
Only a few steel can be use to make transparent lamp mould, mainly DAIDO NAK80, ASSAB S136/S136H, Greodiz 1.2344ESR, HITACHI HPM magic.
Considering the comprehensive polishing property and steel cost, DAIDO NAK 80 is commonly used.
No rough surface cutting and welding allowed, Machined surface is smooth and fine. Polishing is the most important for optical products
Professional hand polishing is the foundation of our existence.
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