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Design Considerations Of Esthetic Parts To Avoid Molding Defects

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Design Considerations Of Esthetic Parts To Avoid Molding Defects

In automotive lighting assembly, the lens, bezel, trim, light guide are regarded as esthetic parts, due to high requirements on visible surface. The flashes, sink marks, impurities, welding lines, scratches, gate marks, flow marks, color inconsistency, and other molding defects are not allowed on A surface. These risks should be observed in moldflow and feasibility study stage. By improving the design jointly with customers, we avoid these risks to ensure the final molded parts are qualified.

Lens Bezel Trim

Lens:

1) To avoid air trap, the thickness of main wall should be at least 0.5mm larger than the side wall, and fill the main wall first.

2) To avoid flow mark, the optical pattern on part is concave by 0.3mm while convex on mold steel. Make radius on every side.

Bezel:

1) The thickness should be same on the texture side. To avoid color inconsistency, it should be no features (such as lock, boss, ribs, etc) on aluminized texture surface.

2) The ribs on bezel surface should be less than 0.3mm in height to avoid any flow marks.

Trim:

1) The gate is put on the lifter. Due to the enhanced ribs on part, the flow marks and gate marks will be appeared after molding. It should be no step or any other features near the gate.