Lamp Injection Moulding

Car lights are a general term for all automotive lighting systems, out of some assemblies there are transparent parts and electroplated parts. It can be said that the part with the highest requirement on appearance of a vehicle is the car lamp. Other than appearance, Its manufacturing process and its effect in practical application are also crucial to a vehicle for guaranteeing the safety during navigation. Therefore, even when do the lamp injection mold design and fabrication we should pay 200% attention and provide the best quality.

The car headlamp reflector (also known as the reflector) is a part of the car headlight lighting system that has a reflection function to avoid direct light. It is located inside the lens and the decorative frame, and is assembled with the lens. Through the lens, it can be seen from the outside of the car light Reflector. It is an outer appearance part always plated with aluminum, high-gloss plating, taking a large area of patterns as surface decoration. Lamps are important safety devices and decorative parts that are indispensable for automobiles. Due to the high temperature working environment and the function of reflecting and concentrating light, the reflector needs to be used with a shrinkage rate of almost 0, and is heat-resistant, flame-retardant, and extremely strong. Creep-resistant precast Bulk Molding Compound (BMC) thermoset molding.

1) The requirements on the appearance surface are extremely high, and spots and gate marks are not allowed on the appearance surface, and defects such as shrinkage depressions, weld marks, and flash are not allowed.

2) The plastic parts are electroplated parts, which have strict light distribution requirements, and the exterior surface is plated with aluminum. The design of the demoulding slope of the exterior surface should be reasonable, and generally at least 5° must be guaranteed.

3) The shape of the plastic part is complex, the surface finish is high, there is no undercut on the inside and outside of the plastic part, no sideways core pulling is required, and the plastic part is a left and right mirror image.

The light distribution requirements of car light reflectors are extremely high, and the roughness of the reflective surface of the mold, processing and assembly accuracy are extremely high. In addition to the mold base lock and guide post positioning, the mold core also needs to be designed to ensure the three-level positioning of the mold is reliable. The area of the light distribution pattern of the polyhedron of the reflector is small and cannot be polished by hand. It is necessary to use a precision five-axis high-speed CNC machining machine with a spindle speed of more than 20,000 revolutions per minute. Using advanced CAM technology and special tools, choose a reasonable processing technology, one-time processing in place. The precision of the cavity is required to be 0.01-0.02mm, and the surface roughness of the cavity is 0.05-0.10 microns.

Every year hundreds of millions of headlights go onto new vehicles and into the automotive aftermarket, so to manage well in all processes and quality control for lamp injection moulding brings magnificent profits.

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