Automotive Lighting Texture Mold

Automotive lighting texture molds are core optical mold insert components for automotive headlamp and ambient lighting systems. The product directly determines the light effect, light spot uniformity, and illumination performance of the vehicle lighting. The typical structure consists of a polyhedral mosaic-style arrangement of multiple independent rectangular reflective micro-facets. The base material is primarily 2344ESR, with a hardness of HRC 48–50, used directly for mass production injection molding. This mold demands extremely high machining standards: the flatness of the reflective micro-facets, the sharpness and straightness of the texture edges, the surface roughness of the mold profile, and the profile consistency of each texture block directly affect optical performance. Tool marks, chatter marks, noticeable color differences, rounded edge collapse, and burr defects are not permitted. Once the edges become rounded or surface tool marks appear, it will cause light spot scattering and blurred light-dark boundaries in the vehicle lighting, leading to product scrapping. The complete solution adopts solid carbide round tools plus PCBN end mills, capable of meeting customer requirements from sample prototyping to mass production.

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Case Details

Machining Steps

1. Datum leveling, rough milling of the blank profile

2. Semi-finishing of the profile base body, leaving uniform finishing allowance

3. Finishing of the mosaic reflective texture

4. Internal corner cleaning and sharp edge forming machining

5. Finishing of the base protrusion, outer diameter, and bottom step

4-Flute Solid Round Corner Radius End Mill:

AHSRF + AHSB complete the roughing of the mold insert and blank, removing the majority of the allowance. High-speed machining with small allowance removal suppresses cutting vibration, establishing a solid profile foundation for subsequent texture finishing.

2-Flute Solid Round Long-Neck Ball-Nose End Mill:

AHSBL is used for semi-finishing of the tapered base body, uniformly leaving finishing allowance and reducing the cutting load for subsequent texture finishing.

2-Flute Solid Round PCBN Ball-Nose End Mill:

The core tool for texture finishing. Five-axis side milling is used to machine each independent rectangular reflective facet, ensuring facet flatness, low surface roughness, and straight texture edges. For extended finishing operations, PCBN ball-nose end mills can be selected to achieve ultra-long mirror-finish machining.

Micro-Diameter 4-Flute Solid Round Flat-Bottom End Mill:

AHSEL is used for internal corner cleaning of the texture, removing the residual fillet left by the ball-nose tool, achieving the sharp edges required for optical performance, and ensuring the light texture boundary of the vehicle lighting.

Solid Round Corner Radius End Mill:

AHSRF is used for finishing the outer diameter of the mold insert base and the bottom protrusion step. The small corner radius enhances tool rigidity, suppresses chatter marks, and ensures dimensional accuracy and surface quality of the datum face.

Case Consultation

If you are interested in our products, please feel free to contact us to discuss potential collaboration.

Phone:0512-67067202
0512-62877712
Fax:+86-0512-62561293
Email:Info@ahno-tool.com
Address:No. 9 Kezhi Road, Suzhou Industrial Park

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