Automotive fog lights are generally turned on when visibility is low, and the penetrating power of light must be particularly strong. Turning on fog lights is to allow others to see the position of your vehicle when visibility is low. The current main light sources include gas bulb light sources and LED light sources. The future development direction is laser fog lights. In order to maintain strong penetration of the light source, the power of the light source is higher, so the heat resistance level of the parts is higher. The fog lamp reflector bowl is usually made of High temperature resistant materials, and the LED light source is usually made of aluminum alloy die-casting to enhance heat dissipation.

 

Fog lamp parts usually require high heat resistance, so the selection of the mould steel and the processing parameters of the reflective pattern are extremely important. Fog lamp housing usually uses PBT+30GF materials with higher heat resistance, so the choice of gate location is very important.

 

Commonly used materials for fog lamp parts

HOUSING	LENS	REFLECTOR	BEZEL
PC+ABS	PC	PC	PC
PBT+GF	Â	PC+ABS	PBT
Â	Â	PBT	Â

 

 

 

Lens mould:

The material of LENS is usually made of PC material. The side surface of the product has lace pattern, and the product surface requires hard coating.

It usually requires mirror polishing on mould surface, and the mould uses side gates to injection. The wall thickness must be optimized before mould machining to avoid air trapping. 5-axis CNC machining for lace patterns around the product edge.

 

Housing mould:

The material of fog light housing is usually made of PBT+GF or PC+ABS. It has high requirement on air tightness and temperature resistance. The dimming shaft hole of the product is usually a compound angle inclined hole.

The parting surface of fog lamp housing mold is complex. Hot runner with manifold is usually used. Before mould making, we will take clear countermeasures to determine the adverse effects of glass fiber on the air tightness of the product. The mould structure is complex, and the design of the core-pulling mechanism for the oblique light-adjusting shaft hole is a key consideration.

 

Reflector mould:

The reflector is usually made of high temperature resistant materials, and the product will be plated with chrom.

The fog lamp reflector mould has a complex parting surface and uses a hot runner with a manifold to injection from the center of the product. The processing of reflective patterns requires a 30,000-rpm high-speed machining center to be processed and formed in a fixed direction at one time, and manual polishing is strictly prohibited. Mould cooling system design is key. The sealing ring should be a high-temperature resistant sealing ring, and there should be heat insulation devices around the mould.

 

Bezel mould:

The product material must be able to withstand high temperatures, and it usually requires plating. There can only be one parting line on the product, and it should has a smooth appearance without flow marks, fogging or other poor appearance.

The bezel mould usually uses hot runner with a manifold. There are sliders around the mould to pull the core, and the sealing ring of the mould cooling system usually uses a high-temperature resistant sealing ring. It requires high precision for machining to assure product does not have any flashes. As the product needs to be plated, It is necessary to avoid slight flashing on the edges, which will have a negative impact on the appearance.

 

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