Innovative injection molding machines for the automotive lighting industry

Injection molding machines

2024/10/01 By Topstar

Automobile headlights comprise reflectors, lenses, housings, light sources, etc. The lightweight design makes more than 90% use plastics in manufacturing. The plastics used, such as PC, PP, ABS, PMMA, etc., can improve headlights’ light transmittance and shock resistance due to their lightweight, impact resistance, and high transparency. Topstar provides innovative injection molding machines solution for “automotive lighting silicone car lights dual-material” and “automotive PMMA thick-walled car lights.” The two solutions can meet headlight plastic products’ optical and precision requirements, ensure light transmittance, thermal stability and shape accuracy, and improve production efficiency and product quality.

Automotive lighting silicone car lights dual-material particular injection molding machines solution

TE ll electric injection molding machine at the core of the solution

Research on silicone car light molding technology in Europe has achieved remarkable results, and it has become an innovative breakthrough in automotive lighting. It has gradually entered the field of intelligent driving. The ADB system is the configuration trend in the future field of intelligent driving lighting. It can intelligently sense vehicle and road conditions, automatically adjust the high beam, and significantly improve night driving safety.

As the raw material of automotive ADB silicone inner lens, liquid silicone can provide higher design flexibility than traditional optical lens materials. It can manufacture high-precision and complex automotive silicone inner lens products. It also has excellent heat resistance and anti-yellowing properties, which ensures the stability of the lens in the entire car. For silicone headlight molding technology, Topstar has launched a dedicated injection molding solution and secondary injection molding process with TE ll electric injection molding machine as the core to ensure that the product meets optical standards.

Two independent injection units

This solution’s TE ll electric injection molding machine has two independent injection units, which can efficiently inject two materials in sequence. The injection molding machine forms the basic structure by first injecting the PC material. Then, it injects the raw silicone material to complete the upper structure, reducing assembly steps, improving production efficiency, and achieving product effects that traditional single-color injection molding cannot match.

High stability template

Wide support feet provide stable dynamic support to protect the mold and machine better. It adopts a non-contact tie rod that does not require lubrication, which can reduce pollutants and the column’s strain. It also has a linear guide rail, low damping, smoother operation, and more sensitive low-pressure mold protection.

Topstar provides one-stop services, from raw silicone materials to mold design and injection molding equipment to solutions for customers in the automotive lighting industry to meet the market demand for high-end automotive lighting products.

Particular injection molding machines solution for automotive PMMA thick-walled headlights

The automotive PMMA thick-walled headlight solution targets the internal stress and bubble defects that may form in the thick-walled headlight lens during high-pressure injection molding.
This solution performs secondary injection molding on the headlight lens with a wall thickness of 35mm, significantly improving product quality and optical performance and shortening the molding cycle.

Direct pressure injection molding machine at the core of the solution

The automotive light guide machine adopts a direct pressure injection molding machine with a clamping structure, which can ensure that the clamping force is evenly distributed in the center of the template, the template parallelism and the perfect fit of the mold, which is conducive to exhaust and effectively solves the bubble and under-injection problems of light guide products in production. Through the control of critical parameters such as high injection pressure and low speed (uniform speed), it can comprehensively solve the problems of yellowing, shrinkage, shrinkage, shrinkage and black spots that may occur in the production process of light guide products, ensuring the high quality and optical performance of the products.

TH-2200-Straight-Pressure-Injection-Molding-Machine

At the same time, it is equipped with an optical-grade dedicated shooting platform, a forward movement design for the shooting platform, and a double-axis oil cylinder to further enhance the accuracy and consistency of injection. In addition, it is equipped with Topstar’s six-axis robot as a back-end automation system to accurately grasp semi-finished products for the first injection and precise placement of secondary injection, ensuring the dual improvement of production efficiency and product consistency.

Make injection molding easier.

Topstar will continue to understand customer needs sincerely, follow the development trend of the automotive lighting industry, provide customers with more suitable solutions, provide more innovative support, and make injection molding easier.

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Innovative injection molding machines for the automotive lighting industry

Automotive lighting silicone car lights dual-material particular injection molding machines solution