Dongfeng Sokon Tail Lamp Photometric Lens

Challenge:
The main challenge was to achieve three different technical requirements on one part at the same time. The product required a bright mirror-like appearance in specific areas, precise optical texture in the functional regions, and stable three-shot molding performance throughout the entire process. It was necessary to ensure accurate positioning and bonding between the three shots while also maintaining high surface quality and clear texture replication. Any instability in mold alignment, material flow, temperature control, or molding parameters could lead to defects such as poor bonding, flow marks, weld lines, gloss inconsistency, texture distortion, or deformation.

Solution:
We optimized the three-shot mold structure and injection sequence to ensure accurate positioning and reliable bonding between different materials. High-precision machining and fine polishing were applied to the mirror-finish areas to achieve the required bright surface effect. For the optical texture areas, the mold surface and processing parameters were carefully controlled to ensure accurate texture replication and stable optical performance. In addition, the gate layout, cooling system, and molding parameters were optimized through mold trials to improve filling balance, reduce defects, and ensure consistent appearance and molding quality.