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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.
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.
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.
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.
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.
Assembly Steps
1. Accessory parts
2. Install the o ring
3. Install the PCB
4. Assemble the light-cup
5. Light-cup install
6. Gluing
7. 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.
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.
