Outdoor LED Light Cover Mould ABS Injection Molding

Our Services: Mold Design; Injection Mold Tooling(CNC/EDM); ABS injection molding Mold Material: 718H Steel Cavity Number: 1+1 Part Material: UV-resistant ABS Part Color: White, Grey

About the Client

This client is an lighting designer based in Canada, who is primarily involved in designing and developing led lights. Their establishment offers a diverse range of LED lighting products, including LED light bulbs, LED high bay lights, UFO high bay lights, and other types of commercial lighting.

Last year, he found our company from our website and expressed an keen interest in our services. He wanted to have a custom-made outdoor LED light body box and lid created from durable UV-resistant ABS material. Our task was to create a new mold that aligned with the design drawings he provided, and then began mass production of the LED light housings.

Design for Manufacturing Review

After receiving the customer's 3D design drawings, our engineers conducted a thorough analysis and crafted a detailed Design for Manufacturability (DFM) report. This report included a comprehensive evaluation of various aspects of the product, such as injection structure, parting line, draft angle, and others. Our Alpine Mold Engineer team collaborated closely with the client to make slight modifications to the design, enhancing the product's manufacturability while still retaining the original design intent.

Mold Design for led light covers

Mold Design for led light covers

Plastic Injection Mold Process

Mold Design and Manufacturing

Once our engineers finalize the mold design and receive approval from the customer, we begin the mold manufacturing process for led light Parts. Our skilled technicians use state-of-the-art machinery and techniques to craft the mold, ensuring that it is precise and of the highest quality. It takes around 6 weeks.

Mold Assembly and Mold Testing

Once the mold has been manufactured, our team proceeds with mold assembly. This involves carefully fitting together all the components of the mold to ensure that it is properly aligned and functions as intended. After assembly is complete, we conduct rigorous testing. This includes testing for factors such as accuracy, durability, and consistency. If any issues are identified during testing, we work quickly to make any necessary adjustments or repairs to the mold.

ABS Injection Molding Process

T1 sample Confirmed

After the samples are finished, our quality control team conducts a thorough inspection to ensure that the finished products meet the client's specifications and requirements. We use advanced 3D inspection equipment to measure the dimensions and characteristics of the products, and we maintain detailed records of every product produced. The samples and a full-size report was sent to our customers for their reference.

Mass Production

Once the T1 sample has been confirmed by the client, we move forward with mass production. Our team utilizes the same high standards and quality control measures throughout the mass production process to ensure that every product meets our client's expectations. Our skilled technicians work efficiently to ensure timely delivery of the final products.

EDM Machining works

Mass Production for LED light covers

Cut Injection Gate by CNC machining

After the injection molding process, we perform post-processing by using CNC machining to precisely cut away the injection gate from the molded part. This process helps to create a clean and precise final product. Usually we use manual scissors to cut off the gate, but for this particular gate of led light covers, we use CNC machining instead. There are two reasons: firstly, the cover has an internal injection point that features a curved surface, which is difficult to cut manually. Secondly, we need to ensure that the gate position is even and aesthetically pleasing.

Conclusion

In conclusion, Alpine Mold has successfully delivered high-quality LED light covers essential for our customer's lighting solutions, enabling them to quickly capture market share. With over 22 years of expertise in plastic injection tooling, injection molding, and digital manufacturing, we are ready to support your needs. If you have a new project that requires our services, please don’t hesitate to contact us—let's collaborate to bring your vision to life!