SERES AITO M5 Headlamp Bezel

Challenge:
The main challenge was to achieve stable two-shot molding while accurately replicating the optical texture on the visible and functional surface. The part required precise positioning and reliable bonding between the two shots, while the optical texture needed to remain clear, uniform, and consistent to support the final lighting effect. Any instability in mold alignment, material flow, temperature control, or molding parameters could lead to poor bonding, flash, color mixing, flow marks, weld lines, texture distortion, uneven gloss, or unstable optical performance.

Solution:
We optimized the two-shot mold structure, positioning system, gate layout, and cooling system to ensure accurate alignment and stable bonding between the two shots. The optical texture area was processed with high-precision machining to ensure clear and consistent texture replication. During mold trials, mold temperature, material temperature, injection speed, holding pressure, and cooling time were fine-tuned to reduce defects and achieve stable two-shot molding performance with consistent optical appearance.