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Interior Led Lamp Component Parts Manufacturing

Manufacturing Process Injection Molding Service
Parts Material ABS
Mold Type Rapid Tooling
Application Industry Automotive
Surface Treatment None
Tolerance(Accuracy) 0.01mm

Notes:

We have pre-market confidentiality agreements with all of our customers. All the cases you see have been communicated with our clients. We have mosaiced some sensitive information. All the pictures are taken from FirstMold’s internal shooting, thanks for your support and cooperation~

What strategies does FirstMold employ to minimize production lead times for LED lamp components?

We utilize lean manufacturing principles, rapid tooling techniques, and automated processes to minimize production lead times. Our project management teams also ensure that all phases of the production process are optimized for speed without compromising quality.

Can FirstMold manufacture exterior automotive lighting components using rapid tooling and injection molding?

Yes, we specialize in the manufacturing of exterior automotive lighting components such as headlights, tail lights, and indicator lights using rapid tooling and injection molding. These components require high precision and adherence to strict automotive standards, which our advanced molding techniques and materials selection cater to effectively.

What options does FirstMold provide for lighting components in commercial spaces?

We manufacture lighting components suited for commercial applications, including light diffusers, lens covers, and light housing units. Our capabilities include producing large-scale and custom-designed parts that meet the specific aesthetic and functional requirements of commercial lighting projects.

How does FirstMold support the production of precision optical components?

Our production capabilities extend to precision optical components such as lenses and prisms for cameras and other optical devices. We use specialized injection molding processes to achieve high clarity and precise dimensional tolerances required for high-performance optical applications.

What advanced materials does FirstMold work with for high-temperature applications?

For high-temperature applications, we work with advanced engineering plastics such as PEEK, PEI, and PPS. These materials are known for their ability to withstand extreme temperatures while maintaining structural integrity and performance, ideal for automotive under-hood components, aerospace parts, and industrial machinery.

Interior LED Lamp is an essential component that provides illumination in car compartments. It is a combination of plastic and aluminum materials that are processed through injection molding and mold-making processes. One of the most important factors in the production of Interior LED Lamp is the design and manufacture of its components, particularly the reflector and lens.

The reflector is a key component that directs the light from the LED bulb toward the lens and eventually illuminates the car compartment. It is typically made of high-quality plastic material and shaped into a parabolic or elliptical form to ensure optimal light reflection. The design and production of the reflector require precise specifications to ensure the quality and efficiency of the final product.

The lens, on the other hand, is responsible for distributing the light from the reflector evenly throughout the car compartment. The lens is typically made of high-quality acrylic material that is shaped and polished to achieve the desired level of light transmission and diffusion. The production of the lens also requires precision in terms of design and manufacturing to ensure the highest level of quality and functionality.

The Interior LED Lamp
The Interior LED Lamp

Efficient Tooling Production for Interior LED Lamp: A Case Study

Our client approached us with an inquiry for tooling products, specifically for Interior LED Lamp, with a requirement of 1K quantity for their marketing needs. Our sales team responded promptly within 12 hours, which is our standard time for production tooling quotes. However, for rapid tooling with a simple structure, we were able to reduce the time to 6 hours or even less, providing our customers with shorter waiting times and allowing them to have more time for assessment.

After good communication, we confirmed the use of LG CHEM LUPOY RF3208 solid white and Bayer Makrolon PC2647 clear materials for the job. The RF3208 material was chosen for its good transparency, high-temperature resistance, and wear resistance, making it an ideal material for the LED lamp. The material choices were based on the client’s design requirements and suggestions from our CAD engineers.

Moving forward, we entered into the DFM communication step, where we ensured that the design for the tooling products was optimized for the injection molding and mold-making process. Our team of engineers worked closely with the client to ensure that the design was suitable for the manufacturing process and made suggestions to improve the product’s quality, performance, and efficiency.

3D model of the LED lamp component parts left view
3D model of the LED lamp component parts left view

Design for Manufacturing (DFM) Process for Interior LED Lamp

Design for Manufacturing (DFM) is a crucial step in the manufacturing process that ensures the product’s design is optimized for efficient and cost-effective production. For the Interior LED Lamp project, DFM was done in 1 to 2 days after reviewing the 3D model. This step allowed our team to identify potential manufacturing issues and suggest design modifications to the client before moving forward with tooling.

After the initial review, our team began to create the DFM report to show the design scheme to the client. The report included details such as parting line, gating, ejection, and wall thickness. By presenting the DFM report, we were able to discuss and resolve any issues with the client, ensuring that the design was optimized for manufacturing.

DFM view of the reflector part
DFM view of the reflector part

Based on the finalized DFM report, we proceeded with the tooling design process. Our team of experienced mold designers used the latest software to create the mold design, ensuring that all aspects of the design were carefully considered. The tooling design was optimized for the chosen materials, LG CHEM LUPOY RF3208 solid white and Bayer Makrolon PC2647 clear, ensuring that the materials were utilized efficiently and effectively.

DFM view of the len part
DFM view of the len part
Tooling design of the LED lamp component parts
Tooling design of the LED lamp component parts

Parts Injected and Tested & Mold Modified

In order to ensure the best quality, we implemented rigorous testing protocols to detect any flaws or defects in the parts. Any issues that were detected were addressed immediately, and our team worked tirelessly to make sure that the final product was of the highest quality.

Mold photos and field processing photos of LED Lamp Component Parts
Mold photos and field processing photos of LED Lamp Component Parts

Assembly Steps

1. Accessory parts

Assembly Step one Accessory parts
Assembly step two install the o ring

 2. Install the o ring

3. Install the PCB

Assembly step three Install the PCB
Assembly step four Assemble the light-cup

4. Assemble the light-cup

5. Light-cup install

Assembly step five Light-cup install
Assembly step six Gluing

6. Gluing

7. Finish

Assembly step seven Finish

Quality Control

We take pride in our QC department being the esteemed golden supplier. Our meticulous inspection process ensures that all parts are flawless, with every detail scrutinized against the 3D model to ensure dimensions are within tolerance. Our comprehensive checks cover running-dimensions, lighting, sealing tests, and more.

sealing test of the finished led lamp component parts
sealing test of the finished led lamp component parts
Dimension Inspection
Dimension Inspection
Lighting Performance Test
Lighting Performance Test

Conclusion

In conclusion, the Interior LED Lamp case study showcases how injection molding and mold making processes can be effectively utilized to create high-quality LED lamp components. By employing a customer-focused approach and utilizing advanced technologies, the team was able to provide a quick turnaround time, while maintaining a strong focus on quality control and design for manufacturing. The success of this project highlights the importance of effective communication, collaboration, and a commitment to meeting customer needs in creating superior products.

1. Warp and Deformation:

  • Requirement: No more than 0.1% warpage allowed on any dimension of the component.
  • Justification: Warpage can affect the assembly and optical performance of LED lamp components, which must fit precisely within specified assemblies.

2. Sink Marks:

  • Requirement: Sink marks must not exceed 0.2 mm in depth on any visible surface of the component.
  • Justification: Sink marks can detract from the aesthetic quality of the product and suggest poor structural integrity, impacting customer satisfaction.

3. Short Shots:

  • Requirement: All components must be fully formed without any short shots.
  • Justification: Short shots can result in incomplete parts that fail to meet functional requirements, leading to high rejection rates and increased costs.

4. Burn Marks:

  • Requirement: Components must be free of any burn marks.
  • Justification: Burn marks can compromise the structural integrity and visual appeal of the components, making them unsuitable for high-quality lighting applications.

5. Flash:

  • Requirement: Flash must not exceed 0.05 mm on any part of the component.
  • Justification: Excessive flash can interfere with the fit between components in assembly and requires additional labor to remove, increasing production costs.

6. Jetting:

  • Requirement: No jetting allowed on any surface of the component.
  • Justification: Jetting can create weak spots in the plastic, potentially leading to failures in use, especially under thermal stress.

7. Weld Lines:

  • Requirement: Weld lines must not be located on any critical mechanical or optical paths.
  • Justification: Weld lines can weaken the part structurally and optically, which could affect the performance and durability of LED lamp components.

8. Color and Clarity Consistency:

  • Requirement: Color and clarity deviations must not exceed ΔE 1.0 on a CIE Lab scale across multiple batches.
  • Justification: Inconsistencies in color and clarity can result in noticeable differences in lighting quality and are especially critical in applications where multiple LED components are used together.
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