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Some Ways To Make Thick-Wall Projector Lens Molds

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Some Ways To Make Thick-Wall Projector Lens Molds

LED thick-wall projector lens becomes popular in automotive industry. The biggest challenge is to develop an economical process for the lens, since the cooling time increases squared with increasing wall thickness.

Toolsong has started its research and development on thick-wall projector lens molds since 2015. To reduce the moulding cycle time, we’ve managed to deal with it through technical innovation.

In gate design, we usually consider edge gate, which is better for low pressure and low speed moulding. We can use customized injection machines for thick-wall molding ranging from 400 to 600T, machines with auxiliary equipment for in-mold rotating, or 2K/3K rotational molding machines.

Led Thick-Wall Projector Lens Becomes Popular In Automotive Industry

If using 1k molding machine, we can make overmold. The multi-layer moulding is achieved by shifting parts in each stage. When the 1st shot is done, take out the part and put it in another cavity for 2nd shot, then take out the 2nd part for 3rd shot. The problem is part qualification rate is not so ideal.

Mold For In-Mold Rotating Moulding

If using 2K/3K moulding machine, we can make 2K/3K mold. The production principle and processing technology are like 2k/3k lens moulding.

Also, we can make the mold for in-mold rotating moulding. With this method, we can reduce cycle time by half. For example, this projector lense is 30mm thick, the cycle time can be 6-7 minutes instead of 14-15 minutes. However, the mold manufacturing cost is very high.