Name: China Injection Mold for Auto Lamp Manufacturers Suppliers Factory - Customized Service - Euromicron Mould Engineering
Brand: Euromicron
SKU: 266084837

Key Points of Auto lamp Injection Mold Design

Automobile, as the main means of transportation for human, are becoming more and more popular. Meanwhile, the appearance of cars is becoming more and more diversified and the shape of headlamps is getting closer and closer to the shape of sports cars, which is very sporty. This brings new demands to the mold design. The appearance requirements of automotive lamps are high; several important parts are transparent parts, electroplated parts, etc.

It can be said that the parts with the highest appearance requirements of the automobile are the auto lamps, so the mold design and manufacture requirements are extremely high.

This article mainly focuses on some design points of the Auto lamp injection mold:

Lens molds are generally left and right lens common mode. Moulds are large and the parting surface is complicated. Therefore, the molded part and the Plate adopt an integrated structure, that is, the fixed mould A Plate of the mold is a fixed molded part,and the movable mould B Plate is a movable molded part. The advantage of this structure is that the structure is compact, the strength and rigidity are good and the mold volume is small, which can reduce some cumbersome processes such as opening the frame, arranging the frame and manufacturing the wedge.

1. The parting surface is smooth and flat, with no wrinkle on the constructed surface and no small facet appears (easy to knives during CNC machining, reducing the machining accuracy). Build the parting surface with the extended surface, mesh
surface and the sweep surface as far as possible, or extend 10-20mm sealing surface first, then make stretching surface, transition surface and the size design of sealing surface mold. High-speed machining is required when finish machining for the Auto lamp Injection mold surface and the parting surface; the speed of the machine tool spindle is guaranteed to be at least 15,000 rpm.

2. Clearance design: The width of mold parting surface is 30MM, and apart from the area of parting surface, fixed mould and movable mould should keep space 1mm. and no finish machining is needed during processing, which can reduce the
processing time. Keep-space is not only for peripheral parting surface, but also the large-area parting surface. Special note: The exhaust slot is included in the width of the mold parting surface. The supporting block should be designed in a large keep-space area to ensure the uniform force of the mold and avoid the flashing when long-term production of the mold. The protruding position is designed to be chamfered, the recess is designed to be rounded, and the larger chamfers and rounded corners are designed as much as possible. While designing the keep-space of the kiss-off hole's area, the vent hole should be designed in the fixed mould or the movable mould to facilitate the discharge of the compressed air when the mold is closed.

3. At present, the angle between the parting surface of the general lens and the mounting surface of the mold is very large. Many types of automobile headlamps have reached or exceeded 45º, which will cause a large lateral force when the mold
is injected in the lens length direction and prone to happen side slip and the unilateral opening of the mold, thus the product produced is unevenly fused, the parallel light passing through the lens is refracted, and the assembled headlamp may
not meet the detection requirements of the vehicle light line. The solution is to evenly lengthen the mold on both sides of the lens length direction, and at the same time, the fixed mould and movable mould interlocks, and the wear block is added at the position of the stop.
4. The fixed mould and movable mould of the lens molds are all high-gloss surfaces. During the injection molding, vacuum areas are generated on both sides of the fixed mould and movable mould. The movable mould sides generally have a retracting slider, and the air enters when the mold is opened, which will make the injection parts unbalanced in force and side-turning and scrape the parts. Therefore, it is necessary to make an undercut of no more than 1 mm when necessary in the inner side of the lens circumference.
The above just introduces some points of the design about the Auto lamp injection mold. It should be pointed out that many beginners think that the lamp molds are bilaterally symmetrical - this is a serious misunderstanding. For example, the
light-emitting surface of the reflector is left and right symmetrical; it's just a symmetrical shape. In addition, the installation position of all lamp installation is consistent with each other - It must not be a mirror image relationship.

FAQ

1.What are the key design considerations for auto lamp injection molding?

a. Material Selection
Lenses: Use PC (Polycarbonate) or PMMA (Acrylic) for high clarity, impact resistance, and UV stability.
Housings: Use PP (Polypropylene), PA (Nylon), or ABS for durability and heat resistance.
Reflectors: Typically PC-ABS with metalized coatings for optimal light reflection.
b. Optical Performance
Lens Clarity: Design smooth surfaces to avoid light scattering.
Light Guides: Ensure even light distribution using optimized prism or micro-optical structures.
Wall Thickness: Maintain uniformity to prevent flow marks and optical distortion.
c. Mold Design Considerations
High Precision: Maintain tight tolerances (±0.05mm or better) for optical accuracy.
Venting & Polishing: Proper venting and high-gloss polishing (SPI A1) are essential for optical parts.
Gate Location: Place gates in non-optical areas to avoid weld lines affecting transparency.
Cooling System: Uniform cooling channels prevent warping and residual stress.
d. Warpage & Shrinkage Control
Rib Design: Use ribs for strength but avoid excessive thickness to minimize sink marks.
Material Flow Balance: Optimize flow paths to ensure even filling and reduce stress concentration.
e. Assembly & Sealing
Snap Fits / Screws: Design precise connection features for easy assembly.
Gasket / Seal Integration: Ensure waterproofing and dust protection for long-term durability.
f. Molded-in Features
Bosses & Mounting Points: Keep smooth transitions to avoid stress points.
Light Diffusing Patterns: Use microtextures to improve diffusion and prevent hotspots.

2.What factors affect the cost of auto lamp injection molds?

The cost of auto lamp injection molds depends on several factors, including design complexity, materials, manufacturing processes, and mold lifespan. Here's a detailed breakdown:
a. Mold Complexity & Design
Lamp Shape & Size: Larger and more intricate designs require more machining and material.
Optical Features: Headlights and taillights often have complex lens patterns and light guides that require high-precision machining.
Multi-cavity vs. Single-cavity: Multi-cavity molds increase efficiency but cost more upfront.
Parting Line & Ejection Complexity: More complex ejection mechanisms, like lifters and sliders, increase costs.
b. Mold Material & Components
Steel Grade: High-wear areas need premium steel (e.g., S136, H13, 1.2738) to extend mold life.
Mold Base & Inserts: Standard vs. customized bases and hardened inserts impact cost.
Hot Runner System: Improves material flow and reduces waste but adds to the cost.
Cooling System: Efficient cooling (like conformal cooling) improves cycle times but increases tooling expenses.
c. Manufacturing Process & Precision
CNC Machining & EDM Processing: High-precision machining for fine details costs more.
Surface Finishing & Polishing: Optical lenses require ultra-precise polishing, increasing costs.
Assembly & Testing: Fine-tuning fitment, light transmission, and durability adds to labor costs.
d. Mold Life & Production Volume
Expected Shots: High-volume production molds require durable materials and coatings.
Maintenance & Repairability: Easy-to-repair molds may have a higher initial cost but lower long-term expenses.
e. Regional & Supplier Factors
Labor Costs: Manufacturing in China, for example, may be more cost-effective than in Europe or the U.S.
Technology & Expertise: Experienced mold makers charge more but offer better quality and efficiency.
Lead Time: Faster turnaround often means higher costs due to expedited machining and labor.

Would you like a cost estimate for a specific lamp mold,feel free to contact Euromicron mould.

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