Auto Light Mould
What is Auto Light Mould
Automotive light moulds are used in the manufacturing of automotive light components, including headlights, taillights, turn signal lights, and fog lights. These moulds are typically made from steel and are used for shaping plastic housings of automotive light. The automotive light moulds market is driven by the growth of the automotive industry globally. As the demand for automotive increases, there is a significant need for automotive lighting components, which, in turn, drives the demand for automotive light moulds. Additionally, the increasing focus on safety and the implementation of advanced lighting technologies in automotive are contributing to the growth of the market.
Highlights of Auto Light Mould
Precision Engineering: Auto light moulds are manufactured with high precision, ensuring that the final product meets exact specifications, resulting in consistent quality and performance.
Durability: Auto light moulds are typically made from high-grade materials such as steel P20, 718, H13, DIN1.2344, DIN1.2738, NAK80, ensuring the good looking of product and stable injection molding production.
Design Flexibility: With auto light moulds, manufacturers have the flexibility to create complex shapes and designs for automotive lights, allowing for innovation in styling and functionality.
Reduced Cycle Time: Advanced manufacturing techniques employed in auto light moulds, such as precision machining and optimized cooling systems, help reduce cycle times, leading to increased productivity.
Integration with Automation: Auto light moulds can be seamlessly integrated with automated manufacturing processes, allowing for increased efficiency, reduced labor costs, and improved overall production throughput.
Why Choose Us
Cost Effectiveness
We strive to provide competitive price without compromising on quality, offering you value for your investment.
Timely Delivery
We understand the importance of meeting deadlines. Our efficient processes enable us to deliver your mould on time, keeping your production schedule on track.
Innovation
Our team stays updated with the latest technologies and techniques in mould making, allowing us to provide innovative solutions that enhance your molding production processes.
Customer Satisfaction
Our focus is on building long-term relationships with our customers through excellent customer service and support.
Lens (Material: Transparent PC): Steel for CAV / COR: DIN1.2738 or DIN1.2344 or NAK80 or S136H. The cavity and core steel should be with enough hardness, and the surface is high gloss polished or mirror polished.
The decorative frame ( Material PBT ): Mould Steel: CAV: NAK80 or S136H (HRC33–37), COR: forged steel HRC31–35, the product is highly polished, can not pass whetstone save the mold to 1000# sandpaper and then polish. The cavity side ( reflective surface) can not be welded.
Reflector (Material BMC): The cavity and core are made of 8407 steel (to achieve a high polishing effect), the cavity steel is HRC46–50, and the core steel is HRC44–48. The cavity side (reflecting surface) is high polished, and can not pass the whetstone, save the mold to 1000# sandpaper and then polish, the core side is generally 600# polished.
Auto Lamp Mould Specification
Plastic features: Transparent color, high requirements for the appearance surface, no spots/gate/marks, no bubbles/ fog halo/shrinkage mark/ welding lines, and other forming defects.
In view of the plastic color transparent, the use of an ordinary runner can avoid the plastic color difference, improve transparency, coupled with the plastic surface is not allowed to have gate marks, so use the side gate gating system.
Car light mould adopts the combined cooling system of "vertical cooling water pipe, inclined cooling lines, and splice water well”, and the waterway is arranged along the cavity, effectively ensuring the precision of the plastic parts and the labor productivity of the mold. The plastic parts are ejected out by an ejector block, which is not only stable but also leaves no influence on the appearance of the product.
In the molding of transparent mold, the design of the exhaust system is very important, such as poor exhaust, will seriously affect the quality of plastic parts, in view of the product material for PC, exhaust front-end design for 0.02mm, around the product according to CAE analysis of reasonable design exhaust, reduce the bubble or air trapping caused by local burns and other problems during injection molding.
|
Description |
Automotive lights Injection Mold |
|
Mold base |
LKM; HASCO; DME, etc |
|
Mold cavity&core steel |
P20,2738,718H,738H,NAK80,SKD61,2738, 2344,etc. |
|
Nos of Cavity |
Single or Multi |
|
Finish |
Polishing or texture |
|
Hot runner brand |
YUDO, HUSKYFISA, HASCO, MOLD-MASTER |
|
Product material |
PC, PMMA,ABS,PP, BMC etc |
|
Mold life |
200k-500k shots |
|
Manufacture time (day) |
55-75 days |
|
Packing |
Vacuum+plywood wooden box |
|
Shipping |
by sea |
The automobile headlight decorative frame is one of the most important parts of the headlight, the appearance requirements are strict, the mold needs electroplating treatment. For the automobile headlight decorative frame mold, the design should pay attention to the following points:
Electroplating parts first to avoid welding lines, because electroplating parts have any welding lines will appear, affecting the appearance of plastic parts, the design of the gating system to avoid welding lines, if the welding line is inevitable, it is necessary to try to get it to the non-appearance area, the gating system design to pass the mold flow analysis verification.
The surface of the decorative frame is generally designed with a pattern. When designing the mold, we should pay attention to the depth of the pattern of the plastic parts, which is generally easy to produce flow lines.
Plastic parts material molding process range is small, plastic parts surface easy to produce bright spots and difficult to control. When the mold gating system is designed, the runner should be thick and large, and the gate should be fan-shaped. The maximum width of the gate is about 35~40mm, which is conducive to melt filling.
Decorative frame plastic parts are easy to appear the phenomenon of sticking cavity side of the mold, to solve the plastic parts of the early design prevention is generally:
In the plastic parts easy to stick to the mold packing force of the inner side of the design of the inverted buckle, the depth of the inverted buckle is 0.5~1mm, the inverted buckle is designed near the rounded corner of the plastic parts.
Reinforcing ribs shall be designed on the inner side of the plastic parts corresponding to the large packing force of the cavity side of the mold, and an undercut shall be designed on the pushrod. According to the characteristics of the plastic parts, in the 6 LED light area inside plastic parts to design reinforcing ribs and BOSS column, to avoid deformation of the plastic parts.
The car headlight decorative frame is one of the most important parts of the headlight. The appearance is strict and the mold needs to be plated. For the car headlight decorative frame mold, the following points should be noted when designing:
The electroplating parts must first avoid the weld line, because any weld line of the electroplating part will appear, which will affect the appearance of the plastic parts. When designing the gating system, the weld line should be avoided. If the weld line is unavoidable, try to drive it. In non-exterior areas, the casting system must be verified by mold flow analysis before design.
The decorative frame surface is generally designed with a pattern. When designing the mold, it is necessary to pay attention to the depth of the plastic pattern. Generally, it is easy to generate flow patterns.
The molding process of plastic parts is small, and the plastic parts are easy to produce bright spots and difficult to control. When the mold casting system is designed, the flow path should be thick and large, and the gate should be a fan-shaped gate. The maximum size of the gate width is 35~40mm, which is conducive to melt filling.
The phenomenon of sticking molds is very likely to occur in the plastic parts of the decorative frame. The prevention of the preliminary design of the sticking molds for plastic parts is generally:
In the plastic parts easy to stick mold on the inner side of the design of a large buckle back pattern, back buckle pattern depth of 0.5 ~ 1mm, inverted buckle design in the corner near the plastic parts.
The plastic parts of the fixed mold with a large force on the side of its corresponding plastic parts design ribs, and design on the push rod upside down hook. According to the characteristics of the plastic parts, the ribs and BOSS columns (commonly known as cylinder columns) should be designed on the side plastic parts of the six LED lamps to avoid deformation of the plastic parts.
In this mold design, the area where the plastic parts hold a large force is more than 5 degrees due to the mold draft, and a 0.5mm deep inverted buckle pattern is designed on the movable mold side, so the mold ejection and ejection are smooth and the movements of the various mechanisms are smooth. The mold is safe, stable and reliable, and the mold does not have the phenomenon of sticking the mold. The problem of sticking molds of such plastic parts has been solved successfully. After the mold trial production of this model, the loading effect is good and the dimensions are stable.
Automotive Headlight Reflector Mold Technology
For the automotive lamp reflector mold, the main design points are:
Special injection molding process equipment is required, and injection molding machines that specialize in producing BMC plastics are used. The requirements for injection molding equipment are very strict.
BMC materials are special hard plastics. The design of the heating system and the parting surface design discharge system are required in the mold design. The molded parts must be quenched to improve the wear resistance and die life.
The plastic parts of reflectors are devices that prevent direct light from being reflected on the lights of cars and prevent the direct lighting of the lights. The light distribution requirements are strict. Plastic parts are the most important appearance parts for automobiles. There are many patterns on the surface of plastic parts to make them look beautiful.
The mold design of the BMC material should be balanced in the ejector system, and the pusher specifications should be designed as large as possible, and the number should be as large as possible, otherwise it would cause difficulty in demolding the plastic parts.
Because the draft of the high-light plating part is too small, it will cause difficulty in demoulding. Therefore, the draft angle of the side wall of the reflector part is designed to be as large as possible, and it is generally recommended to be 5 to 10. Of course, the premise is that it cannot affect the function and shape of plastic parts.
Plastic parts must not have sharp corners, and all corners must be designed with rounded corners because the molded parts of the mold are susceptible to stress cracking after quenching.
Note that the holes of the left and right reflectors and the surface of the plastic parts are shifted from side to side, and cannot be designed as mirror symmetry. Because the bulb and the lamp head are not separated, the rest of the features are mirror symmetrical.
Appearance Requirements for Automotive Headlights
Lens
Lens is a transparent piece with a pattern on inner side with a high requirement of appearance.
Decorative frame
Appearance of decorative frame is aluminized and some areas need to be frosted.
Lamp housing
Lamp housing is an internal functional part of lamp mould, and assembly requirements of lamp cap hole and back cover hole are high.
Mirror
Mirror are electroplated parts, have strict light distribution requirements, and appearance surface is aluminum plated.
Mold Needs Heating Tube Heating and Strict Temperature Control
Basic injection molding process of BMC material is completely different from ordinary thermoplastic injection molding process. In barrel part of plastic injection molding machine, a dedicated freezer is used for ice water cooling, while in mold cavity core, electric heating is required.
Total electric power of electric heating pipe required for fixed mode can be calculated by following formula:
W=Gcp(Tm-To)/3600yt
G: Total weight of mold including movable and fixed mold, kg
Cp: Specific heat capacity of injection molding mold material, kj / (kg. ℃)
Tm: Temperature required for injection molding mold forming: ℃
To: Room temperature: ℃
Y: Heater efficiency, take 0.3-0.5
T: Heating time, h.
Commonly used electric heating tube has a diameter of 15.8 mm, which can increase mold temperature quickly. According to experience, mold heating power can calculate required electric heating tube power by (40-50)W/kg. Molding surface of plastic part is 40-50mm away from electric heating tube, and distance between two electric heating tubes is 80-100mm. In order to improve heating efficiency, an 8mm thick bakelite insulation board is required on all four sides of fixed mold. Since electric heating tube has no positive and negative poles, it can be connected in series, but temperature controller socket can not exceed 3.6KW per group. Temperature of each group of electric heating tubes is controlled by a group of thermocouples. Thermocouple should be in the center of temperature field of electric heating tube of this group, thermocouple head needs to be in effective contact with cavity, which is beneficial to accurately control temperature.