Dongfeng Liuzhou Motor Headlamp Lens

Challenge:
The gate design had to ensure stable filling while avoiding visible gate marks, flow lines, weld lines, and air traps. At the same time, the product required a high-gloss surface, so any machining marks, polishing defects, or unstable molding parameters could affect the final appearance.

Solution:
We optimized the gate location and gate size based on the product structure, flow path, and visible surface areas. Mold-flow analysis was used to check filling balance, weld line position, pressure distribution, and air trap risk. To meet the high surface finish requirement, precision machining and multi-step polishing were applied on the mold surface. The gate area was carefully processed to reduce gate marks. During trial molding, mold temperature, material temperature, injection speed, holding pressure, and cooling time were adjusted to achieve stable filling and a smooth, glossy surface.