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The Design Concept of Automobile Lighting and Its Prototyping

by:Vowin Rapid Prototyping     2023-02-02
Car lights include headlights, taillights, fog lights, etc. All kinds of lights have different purposes. If you are an automotive lighting manufacturer, have you done any research on the impact of headlights? Do you know the prototyping process in the design phase of automotive lamps? Shenzhen Woneng Rapid Prototyping will answer for you 1. Design requirements for automotive lighting 1.1 Headlights Automotive headlights, also known as automotive headlights, as the eyes of the car, are not only related to the appearance of the car owner, but also related to night driving or bad weather It is closely related to safe driving under these conditions. The material of the headlights needs to ensure that the vehicle has bright and stable lighting when driving at night, so that the driver can clearly distinguish objects within 100 meters. At the same time, there must be anti-glare devices to ensure the safety of driving at night. Material and performance requirements: Part name Production material Prototype Material performance requirements Light distribution mirror PCPMMA, PC scratch-resistant, transparent, UV stable bezel PC, PCHT, PBT, PBT/PETPMMA, ABS heat-resistant, electroplating, high surface quality light guide PCPMMA , PC transparent, UV stable reflector PC, PBT, PPS, BMCABS, Aluminum high heat resistance, high rigidity, electroplating, high impact resistance shell PP+T40, PP+T20ABS dimensionally stable, heat resistant 1.2 Tail lights Tail lights are transmission Signal lights for brakes, steering and other important information. Due to its frequent use in the city, the performance requirements for the material are also high. The material must have high heat resistance, good processability, wettability and bright colors. Material and performance requirements: Parts production materials Prototype material performance requirements Light distribution mirror PMMAPMMA PC scratch-resistant, transparent, UV stable shell ABS, PC/ABS, ASAABS dimensionally stable, heat-resistant inner light distribution mirror PC, PCHTPMMA PC transparent, UV stable Bulb holder ABSABS Dimensionally stable light guide PCPMMA PC Transparent, UV stable 1.3 Fog lights In low visibility conditions, such as rain and fog, the effect of headlights is limited. Therefore, fog lights need to pass through fog and other obstacles to ensure normal sight. Due to the high power and high temperature of fog lamps, the required materials should also have high heat resistance. Material and performance requirements: Parts production materials Prototype material performance requirements Light distribution mirror PC + hard coating, PMMAPMMA PC scratch-resistant, transparent, UV stable shell PCHT, PEI, PBT/ASA, LCP, PC/ABSABS Dimensionally stable, heat-resistant reflection PCHT, PEI, PCABS, high heat resistance, high rigidity, electroplating, impact resistance 2. Automobile lighting prototype manufacturing At present, the main technologies used in the field of automotive lighting prototype trial production include 3D printing, CNC processing, vacuum composite mold and rapid aluminum mold , each of which has its advantages. The following are the different technical applications of Vowinin providing rapid prototyping services for the design and development of automotive lights: 2.1 Concept and engineering stage: CNC machining CNC headlight prototype machining is characterized by high precision, fast response and short cycle time (Lead time 1-2 weeks), which makes it possible to machine complex shapes in one piece of material. Typically, in the conceptual phase (concept phase) and in the engineering phase (engineering design phase), a part of the headlamp, such as the light pipe or reflector cup, has to be modeled for appearance or function. This need often requires the ability to produce high-precision prototypes in the shortest cycle time with real materials, and CNC is the best choice. Due to the complex structure of the lamp, there are many optical details and undercuts, and even a high-precision 5-axis CNC cannot process the entire part at one time. CNC programming engineers with rich experience in prototype lamp manufacturing need to analyze the feasibility of processing after obtaining the lamp design drawing. For parts that cannot be machined as a whole, they need to provide solutions for disassembly machining, especially for critical surfaces. In the later stage of prototyping, manual post-processing work such as deburring, polishing, bonding and painting is especially important, and will directly determine the final appearance. 2.2 Small batch test stage: Vacuum composite silicone mold is one of the easiest methods in the rapid tooling, with good flexibility and replication performance. Therefore, this technology is widely used in the low-volume production of automotive lamps. For small-volume headlamp parts using silicon molds, it is particularly important to choose manufacturing methods and materials to meet the appearance and performance requirements of different parts. For optics and bezels that require a mirror finish, we typically choose CNC to manufacture PMMA prototypes with a high-quality surface finish. Silicone molds made by this method ensure the perfect look of the casting. For structural parts with low appearance requirements, such as shells, we use RP technology (such as SLA) to manufacture prototypes, and choose AXSON PX223 with excellent temperature resistance as the composite casting material. Share a project: 3. Small batch loading test: rapid tooling materials are mainly mild steel (such as P-20) and aluminum (such as 7075 T-6 aviation grade aluminum). Compared with hard steel, it can increase the processing speed by 15% to 30%, and the polishing time can be shortened by 3 to 10 times, and the weight is lighter, which reduces the manufacturing cost of the mold and shortens the cycle. Additionally, fast aluminum tooling facilitates temperature control, reducing cycle times and eliminating plastic stress. Since the car is in the development stage, it is necessary to evaluate its processing cycle and manufacturing cost, which can be obtained by rapid aluminum moulding. For example, engineers can produce small batches of luminaires through rapid aluminum molds for load testing or pre-marketing. The biggest advantage of the quick aluminum mold is that it has real material and real structure. Not only the response cycle is fast, but also the production cycle and cost can be evaluated reasonably and truly. Compared with ordinary steel molds, the surface quality of the two materials is almost the same. The service life of the aluminum mold is related to the complexity of the product. Although it is much lower than the steel mold, it can also achieve a service life of not less than 1000 times, which is more than enough for the initial load test. Here's the aluminum mold on the taillight assembly:
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