Factors Influencing the Quality of Car Light Molding

Several factors influence the quality of car light molding. The main factors are mold design, materials selection, and manufacturing process. Injection plastic molding is an important technique used to produce automotive lighting fixtures. It can produce highly repeatable components and produces a high quality surface finish.

The most important car light parts are the headlight and the reflector. The headlight is generally transparent, whereas the reflector is usually a mirror image of the left and right sides. Automotive headlights are normally about 30 millimeters thick. However, the thickness of the lens can be as high as 750mm.

Automotive lamps have high design and light distribution requirements. In order to meet these requirements, the lamp mould template is integrated into the original body. Diamond cutting is used to ensure optical requirements. The material of the lamp can be ABS, PMMA, or PP. The machining process requires high processing precision and assembly precision. The lamp material has a wide range of uses, including lighting, safety, and appearance. The material can be customized into assorted colors.

In the plastic mould design, the partsing surface has to be designed to prevent flow marks and to improve wear resistance. The mold should have a parting surface discharge system and a heating system. Moreover, the mold must be equipped with a quenching system to improve wear resistance. The ejection line must also be approved by the customer.

The outer surface of the car headlight reflector is made of Class A curved surface. The gap between adjacent curved surfaces must be below 0.005 deg. There are no thimbles, inlay marks, or reverse buckles on the inner surface of the reflector. The reflector must work in a hot environment. It must also have an attractive design.

The surface of the reflector is highly electroplated. Its outer surface is also covered with aluminum-plated material. The inner surface is made of a high-gloss material. The material has a very high surface appearance, but it also has very poor fluidity. Consequently, the mold requires an overflow tank around the movable template cavity. This requires special injection molding equipment.

The light guide mold has a complex parting surface and often has a serrated pattern. The parting surface is generally made of PC or PMMA. It has a large drop product and the optical requirement is high. The gating system is also complex. The molding cycle is highly dependent on the design of the cooling system.

The car headlight reflector is a complex plastic part. It is composed of two cavities, one on each side of the car. The outer cavity is used to hold the lens, while the inner cavity is used to hold the reflector. The core material is made of BMC, a special hard plastic material. The material has good processing performance but has poor fluidity. The outer surface of the BMC material must be aluminum-plated. The material also has a very high surface appearance and must be electroplated. The gating system is complex due to its thin ring shapes.

Customized Plastic Car Lights Mould