SAIC Headlamp Photometric Lens

Challenge:
The main challenge was to achieve a bright mirror-like appearance while ensuring stable two-shot molding performance. The part required accurate positioning and reliable bonding between the two shots, together with strict control of the visible surface quality. Any instability in mold alignment, material flow, temperature, or molding parameters could cause defects such as poor bonding, flash, color mixing, flow marks, weld lines, sink marks, scratches, or uneven gloss.

Solution:
We optimized the two-shot mold structure, positioning system, parting line, gate layout, and cooling system to ensure accurate alignment and stable bonding between the two shots. High-precision machining and fine polishing were applied to the mirror-finish areas to achieve the required high-gloss appearance. During mold trials, we adjusted the mold temperature, material temperature, injection speed, holding pressure, and cooling time to reduce surface defects and ensure consistent mirror-like surface quality.