Car dashboard lens
Our customers come to us to make molds for car dashboard lenses and ask for optical polishing. Based on the MODA team's analysis of the lens 3D graphics design and the client's needs, we recommend that the client improve the product design. In order to achieve the level of optical polishing, the customer adopted our suggestion and made modifications. In the end, we made perfect T1 samples and our customers were very happy with them.
Challenge
The finished surface should be flat, free of any bumps or dents, and free of structure so that the machine can polish the entire surface. The parting line solution of this product does not meet the polishing requirements. Look at the picture.
The red line is the parting line of the original 3D part design, indicating that the parting surface of the cavity is not a plane, which can only be done by manual optical polishing process, and cannot be polished by optical polishing machine. In this case, a perfect optical finish cannot be guaranteed. What do we do now? See "What We Did."
What did we do: Solution 1
What we did: Solution 1 If there is no impact on assembly and functional quality, we recommend optical polishing only for red shaded surfaces. This allows us to make the red shaded part into a mold insert, which has a flat surface, so we can polish it with an optical polisher.
What did we do: Solution 2
We recommend moving the parting line to the top so that the surface of the cavity is also flat and can be polished with an optical polisher.
Our customers prefer Solution 2. That's the one.
Other technologies
The S-shaped runner reflects our rich experience in transparent lens mold manufacturing. Make the molding debugging more smooth, avoid the injection molding in the gas marks, flow marks and other problems.
Mold flow analysis
Mode flow analysis helps us and the customer understand how the product is shaped, avoiding some unpredictable situations and proving to some extent that the overall solution is feasible.
Result
The mold works well in the injection molding machine, and the samples and products are perfect without deformation.
Specification
|
Part name: |
dashboard lens |
| Part material | Acrylic |
|
Mold cavity: |
2 cavities |
|
Cavity/core steel: |
ASSAB S136 Hardened |
|
Mold Life: |
1,000,000 |
|
Mold size: |
500*550*540 mm |
|
Standard parts: |
DME inches |
|
Polish grade: |
Optical polish |
|
Ejection: |
Level 2 ejection |
Customer evaluation
Dear Jemes：
"Thanks again for all your support. You and the MODA team could not have been more inclusive and professional during the building of this tool."
Best Regards.
Mr. David
After the first sample test, David had this to say:
– I just finished testing six lenses and two components:
– All six lenses are assembled correctly into final assembly.
– All buckles are properly engaged to the shell.
– Buttons really fit all six lenses.
– The trim ring buckle does engage the lens properly.
– The outer and inner surfaces of the visible areas are fine.
– I will make measurements to verify the size.