Dongfeng Fog Lamp Lens

Challenge:
The product required a clear and uniform corn-kernel texture while also meeting ECE optical requirements. The texture had to be accurately machined without affecting the light distribution performance. At the same time, the two-shot molding process required precise material bonding, stable positioning, and strict control of color separation. Any texture distortion, poor bonding, flash, or color mixing could affect both the appearance and the functional performance of the lamp.

Solution:
We optimized the texture machining process to ensure the corn-kernel pattern was clear, uniform, and repeatable. The texture depth, corner radius, and surface finish were carefully controlled to avoid light distortion and surface defects. For ECE compliance, we worked closely with the optical design requirements and controlled the key optical areas during mold design, machining, and polishing. The mold structure and injection parameters were adjusted to maintain stable light transmission and consistent optical performance. For the two-shot molding process, we optimized the rotary or positioning structure, material flow, gate design, and sealing areas to prevent flash, color mixing, and bonding defects. Trial molding was carried out to fine-tune mold temperature, injection speed, holding pressure, and cooling time, ensuring good appearance, stable bonding, and compliance with functional requirements.