SAIC EP39EV Headlamp Housing

Challenge:
The main challenge was to maintain a high-gloss appearance while controlling part deformation and preventing flash during molding. The lamp housing required stable dimensions and clean edges, as any warpage, shrinkage, flash, or uneven gloss could affect both assembly accuracy and final appearance. Since high-gloss surfaces are highly sensitive to molding conditions, strict control of material flow, cooling balance, mold clamping, and injection parameters was required.

Solution:
We optimized the mold structure, cooling system, parting line, and gate layout to improve dimensional stability and reduce the risk of deformation and flash. High-precision machining was applied to the sealing and parting areas to ensure clean edges. During mold trials, mold temperature, material temperature, injection pressure, holding pressure, and clamping force were fine-tuned to achieve a stable high-gloss surface, accurate part dimensions, and flash-free molding quality.