Car Light Mold Design And Manufacturing Solutions

Car lights are an indispensable set of accessories for cars. Whether it is a traditional or technologically fashionable model, the main components of car lights are inseparable from the headlight body, reflector, decorative frame, and light distribution mirror. As the most demanding auto part mold for automotive exterior parts, car lights also have high requirements for the design and manufacturing process of car light molds.

First of all, the challenge comes from the headlight body.

The car light body is an internal functional part. Although the appearance requirements are not high, there are many assembly holes and buckles, which means that the design and manufacture of car light mold may have the following risks:

1. There are many inclined tops, sliders, and inserts in the mold, which are prone to breakage and flash;

2. The structure of water transportation is complex/difficult to cool evenly;

3. The amount of discharge machine added is large/there are many single electrodes

Secondly, for reflectors, we need to design molds in combination with the particularity of product specifications.

The reflector, also known as the reflector, is a part of the automotive headlight lighting system that has a reflection function to avoid direct light and is an appearance part. The surface is high-gloss plated and has a large area texture for surface decoration. Since the reflector needs to work in a high-temperature environment, it is also required to be beautiful while achieving the purpose of reflecting and concentrating light. Therefore, automakers often choose prefabricated bulk molding compound (BMC) thermosetting plastics with heat resistance, flame retardancy, and strong creep resistance for the molding of reflectors.

For the manufacturing requirements of reflectors with strict light distribution and direct aluminum plating, Taizhou Toolsong Mold recommends that attention should be paid to the mold design:

1. The parting surface of the mold cannot be avoided, and flashes are easy to appear;

2. The intersection position and weld line must be accurately analyzed in the previous mold flow;

3. The front and rear mold heating rods are evenly distributed and reasonable to prevent deformation;

4. Eject out and increase the sheath to prevent high-temperature burning;

5. The surface texture profile requires high precision;

6. The mold core should not be disassembled as a whole as much as possible to avoid internal criticism of the product.

Thirdly, for the decorative frame of the car light, attention should be paid to achieving its high surface requirements for mold design.

The lamp decoration frame is a decorative part of the automobile headlight lighting system. It is located inside the lens and assembled with the lens. People can see the decoration frame from the outside of the lamp through the lens. Usually, the manufacturing materials of car lamp decoration frames are PC, PBT+GF, PBT+PET, PA+GF, and surface plating is required.

For this reason, Taizhou Toolsong Mold’s experience is to select high-quality mold materials and pay attention to:

1. The intersection position and welding line must be analyzed accurately in the early stage;

2. The front mold should be smooth and prevent front mold from sticking;

3. Water transport and ejection design to prevent deformation;

4. Pay attention to the texture depth to prevent flow marks

Finally, optical mirrors also require high-quality mold design and mold manufacturing to complete product molding.

The light distribution mirror, also known as the lens, is the outermost transparent part of the car headlight. Generally, the headlights of automobiles are white and transparent, and the rear combination lights are red (or multicolor) and transparent. The surface of the light distribution mirror is a class A curved surface (that is, the gap between adjacent curved surfaces is between 0.001~0.005mm, the curvature change is below 0.005 degrees, and the cutting rate change is below 0.16 degrees.), the outer surface has a super-hard coating, and the inner and outer surfaces are transparent Very demanding.

Mold points:

1. The intersection position and welding line must be analyzed accurately in the early stage;

2. There is line printing control of the inner drawing line, inclined top line, and ejector line;

3. The design of two-color/three-color and multi-color parting sealing surfaces is very important;

4. Pay attention to the texture depth to prevent flow marks;

5. The exhaust design should be fully reasonable and effective;