“Headlight is the eyes of the motorcycle, a great design of the headlight can raise the motorcycle price a lot.”
— Taizhou Xiongshi Plastic Mould Co., Ltdr
Motorcycle almost every 1-2 years need to update the appearance, of course, some classical design can be lasting for some years. But motorcycle is a fiercely competitive industry, more beautiful and more fashion design can bring high quantity sales and high profit. With this reason, motorcycle manufacture need to develop new moulds every year.
①. Headlight housing part design
The primary design normally provided by client, after checked and analysis the part 3D design we will provide part design improvement suggestion to client. With our suggestion, client can change the part design and make it better fitting for injection moulding. Of course, client can require us to change the part 3D design in the condition that paying us the design change charge.
②. Headlight housing mould 3D design
Before starting mould 3D design job, we need to make some information clearly from client. 1. Part plastic raw material. And the best that can get the plastic material detail specification from client, then we can get the detail shrinkage rate, flow rate, etc. information, which are very important for the mould design job. 2. Injection machine detail specification. The injection machine tie bar distance, mold maximum & minimum height, mold open stroke, injection weight, SR size, knock out rods centre distance & diameter, etc. These are very important for carrying on the mould 3D design job.
Once client confirm the mould 3D design, then we can go on the mould steel purchasing and tooling.
③. Headlight housing mould tooling.
Tooling is another most important for the headlight housing mould production. As one of the motorbike plastic part mould, the tooling quality have to meet motorcycle parts mould tooling standard. Just same like the auto part moulds quality standard, which include tooling standard, motorcycle parts mould also have its own quality standard on the tooling.
Just same like most plastic injection moulds, the first tooling process after steel cutting is the cnc milling tooling for headlight housing mould. After this tooling process, the area steel thickness still need to be tooled by 1-2mm, then mould sizes can be exactly what we needed.
After CNC milling tooling, normally headlight housing mould will be going on drilling tooling. Include screw holes drilling, eye bolt holes drilling and cooling lines drilling. But cooling lines drilling tooling machine different, because cooling lines are long, normal hole drilling machine can not fit for this job. So deep hole drilling machine is applicated in this process.
The left picture mould was just finished drilling tooling, the right one mould already finished cnc engraving tooling. The red colour on the holes of the right picture one are the thread. Many holes need to fix the mould spare parts, so need the holes with threads to tight the screws.
Precise tooling is the last most important for every set mould. As this tooling process decide the products sizes precision. Precise tooling include cnc engraving tooling, high speed cnc milling tooling, precise lathe tooling, boring tooling, precise grinding tooling, slow speed wire cutting, EDM, etc. But for headlight mould, precise tooling include cnc engraving tooling, high speed cnc milling tooling, EDM tooling, etc. Detail tooling process was selected according part mould design and quality requirement.
④. Headlight housing mould polish
Automobile parts moulds and motorcycle parts moulds almost all these mould polished by hand. Because these mould need high requested finish polish. And another thing automobile parts and motorcycle parts design are complex, normally can not directly polished by polishing equipment.
⑤. Headlight mould trail.
Headlight housing mould is over molding with some copper inserts. So can not run the mould on injection machine automatically. This is due to the part design, mould design have to be made to fit for that design.
Usually headlight housing need to be painted after injection moulding production. So visible area need be done with good polish.
⑥. Headlight housing mould pictures
