Injection Molding Plastic Parts for LED Lighting

Our Main Services: Mold Design and DFM, Plastic Tooling Making, Injection Molding Plastic Parts Tool materials: S136 Runner system:Cold runner   4 Molds cavity numbers:1+1, 1+1, 1x2, 1x2 Part materials: TRISTAR PC-10FR-(8) Part color:  Grey, black, white, red, blue, yellow

About the Project

The client is from America. He developed and designed this architectural LED lighting, which is used to directly suspended architectural lighting fixture, This product boasts a striking profile and combines cutting-edge technology to make a powerful impact.

He searched us from our website and ask us custom molds to make 4 different shapes of plastic end caps for LED lighting. The end cap styles include flat, chamfer, angle. These parts’ material all use TRISTAR PC-10FR-(8). They require to do texture BOC 2020A surface treatment.

Plastic Resin TRISTAR PC-10FR-(8)

We molded the led light end caps using a special plastic resin called TRISTAR PC-10FR-(8).

TRISTAR® PC-10FR-(8) is a naturally transparent, flame-retardant polycarbonate resin that is produced by Amco Polymers. It has some advantages including improved safety, high impact resistance, good optical clarity, chemical resistance and versatility, etc.

Due to its unique combination of properties, It is suitable to use for lighting fixture plastic parts where fire safety is a concern. We will offer our customer with material certificates and conduct flame-retardant testing to ensure compliance with safety standards.

Design for Manufacturing Review

Our mold engineers comprehensively review every detail of CAD drawingsand pay close attention to the end use of the product . In the report, we will analyze the product's parting line, ejection layout,draft angles, thickness,part Layout and cooling system, etc. By making DFM reports, we often identify opportunities where the design can be refined, making it standardized and simplified, making the design easier for production and use, and reducing the manufacturing cost of the entire product.

Draft Angles

The proper Angles of demoulding can avoid the product top injury, such as top whitening, top deformation and top breakage. The green surface have no draft angle,suggest to reduce material to make 0.5° draft angle.

Undercut

Undercut is a form of structure that cannot be directly ejected from the mold. The pink surface have undercut, suggest to reduce material to make 0.5° draft angle, totally 2 positions.

Part Issues And Proposals

We suggest reduce the chamfer to 0.3mm for all the screw columns, in order to make standard ejector sleeve for ejection.

Injection Molding Process for Led Light

See below injection molding process, you will konw how we made plastic end caps of LED lighting for our clients from quotation to delivery. When the customer received these customized end caps of LED lights, he was very satisfied with the quality of the product and our delivery time. Until now, the customer placed an order again and again from us every 3 months .

1. Request for Quote

Our customer send his part drawing in step format to us and we give him a qotation within 2 days.

2. DFM Report

After our client accepted our price, we started make DFM Report to optimize product design.

3.  Mold Design

Our engineers started to make mold design. Each step will be presented to our customer as the schedule.

4. Injection Mold Tooling Making

We used sink EDM to make some of the deeper features in the mold toolings and added texture to the toolings.

5.  Injection Molding Mass Prodcution

After our customer comfirmed the T1 samples, we started mass production. 

6.  Delivery

Once the parts had passed quality inspections, they were well packed for delivery.

Working with Alpine Mold for Your Next Project

We hope you found this case study informative and that it has provided you with valuable insights that could be beneficial for your upcoming projects. If you have a new project that involves injection molding plastic parts, and you are looking to bring your drawing to life, please feel free to contact us. We would offer you a free quotation and project review as soon as possible!