Our JinYi Mold has successfully developed and delivered precision injection molds for automobile fog lamp frames and lamp housing assemblies for Japanese OEM customers. They are used to produce compact exterior lamp components that require extremely high optical alignment and sealing properties. The mold needs to assemble the left and right parts at the same time. The core challenge is to coordinate the decorative appearance and optical functionality in a very small space to ensure that the decorative ring perfectly matches the bumper molding line. At the same time, the light housing maintains the optical centerline to achieve precise light direction, reliable waterproof performance and long-term durability. The key dimensional tolerance needs to be strictly controlled within ±0.03 mm.
Relying on its rich engineering experience serving global automobile brands, Jinyi Mold provides a full-process solution from optical design feasibility analysis to mass production verification. Avoid risks through comprehensive DFM (Design for Manufacturability) review and mold flow analysis (Moldflow), and use 80 to 1,600-ton injection molding machines for process verification to ensure that the mold meets high-quality, high-efficiency mass production needs.
Key points of engineering technology
Optical and structural design:
Fully parametric 3D mold design based on UG/CATIA, focusing on optimizing the parting line position, gate layout, and balanced wall thickness of 2.0–2.6mm to ensure zero-defect demoulding, and structurally guarantee optical alignment accuracy and component strength in long-term production.
Precision manufacturing of optical quality:
The mold is made of high-strength, corrosion-resistant mirror steel such as S136 and NAK80, and processed through high-speed CNC and EDM to achieve a mirror polishing standard of Ra ≤ 0.05 µm in the visible area, ensuring the consistency of surface gloss and texture. The balanced layout of 15-25 cooling circuits effectively controls deformation and ensures the stability of the optical geometry.
Mass production and flexible design:
A dual-cavity layout is used to mold the left and right parts at one time, and interchangeable inserts are designed to quickly adapt to changes in future shapes or sensors/light guide strips, thereby increasing the life cycle value of the mold. Multi-zone cooling systems reduce production cycle times by 10–15%.
Validation and Quality Assurance
Each set of fog light decorative bezel molds needs to undergo systematic verification in compliance with OEM standards to ensure mold performance:
Multi-round mold trial optimization:
The structured mold trial process from T0 to T3 gradually debugs and locks the best process parameters to ensure the stability and repeatability of production.
Full-dimensional precision inspection:
A three-dimensional coordinate measuring machine (CMM) is used to conduct full-size measurements of buckle features, assembly radius and optical reference points; at the same time, optical inspection is performed to verify the consistency of the optical path to ensure no distortion and reduce dimensional data errors.
Assembly assembly test:
The produced sample is actually assembled with the fog lamp provided by the customer to verify the fit, sealing performance and overall optical effect of the assembly.
Delivery and support
When the mold is delivered, we will provide a complete mold technical documentation package, including: 2D/3D design files, DFM and mold flow analysis reports, CMM dimensional inspection reports, material and hardness certificates, trial mold samples and maintenance guides to ensure that customers can take over seamlessly and achieve stable mass production.
This project reflects JinYi Mold’s professional engineering capabilities in the field of precision automotive lighting and exterior molds. We are committed to transforming complex optical and appearance requirements into stable and reliable mass manufacturing solutions.
About Us
Jinyi Mold was established in 1998 and is headquartered in Dongguan, Guangdong. Our professional team provides injection mold and die-casting mold services, providing you support in every aspect from design, manufacturing to final assembly.
Production equipment:
dozens of CNC machining centers (gantry & 5-axis), injection molding machines (80-1600 tons), EDM machines, automation equipment, etc.
Scope of services:
Establish solid partnerships with Europe, Australia and Asia to carry out international export business.
Company production capacity: A 13,000㎡ production base in Maoming (built in 2022), backing an annual turnover surpassing 150 million RMB.
Honors and qualifications:
Possess High-Tech Enterprise Certification, ISO9001:2015 Quality management system certification.
Logistics and freight:
Logistics follows international transportation standards, and packaging is packed in reinforced wooden boxes, filled with PE foam and wrapped in moisture-proof bags.
Marketing: Selina Chan
WhatsApp:+8618969686504
Email:selina@jy-mould.com
Contact us to discuss how we can support your project needs
Please know that when you choose Jinyi Mold, we are not only a supplier, but also a Chinese manufacturing partner with 25 years of experience in mold design, manufacturing, and assembly.
