Injection Mold Design & Build of an Automotive Head Light Extension

At Eagle Mold Co., Inc., we designed and built the tooling highlighted here for an injection molder supplying parts to the automotive industry. This particular mold is used for the production of a headlight extension. With our 30+ years of experience in many industries with complex molding needs, we had the ability to deliver a turnkey mold package that met the client's quality, surface finish, and cycle time requirements.

Using our state-of-the-art CAD/CAM software, we used a computer model of the part to design a production mold. Before we build anything, it is our policy to simulate mold performance under production conditions to validate and verify the integrity of our design. This process allowed us to test and evaluate various design aspects as well as different production scenarios to optimize filling, packing, and cooling, which are three critical aspects of producing a consistent quality injection molded part.

When it comes to injection molds, making the right material choice is critical. Over built molds are a waste of financial resources, while under built molds are subject to premature wear and can compromise production rates. By frequently communicating with the client, we gained a firm understanding of how many parts the mold was expected to produce, the surface finish requirements, target cycle times, and the resin material they were using. We both agreed that lens grade P20 steel was the best choice for the tooling.

Our sophisticated machinery in the hands of our trained professionals allowed production to take place at a good pace. Primary operations took advantage of our high speed 5-axis milling capabilities, and EDM machining enabled us to achieve close dimensional tolerances of ±0.0005". Finishing operations involved creating an SPI A2 surface to ensure a good cosmetic appearance on the final part.

This mold was very large. Featuring dimensions of 35" in length x 35" in width x 35" in height, it weighed a considerable amount when complete. We took great care when maneuvering the workpiece around the shop floor to ensure it was not scratched or in any way damaged before final packaging and shipping to the client in Ohio.

If you would like to learn more about our mold design and build capabilities, contact us today.