Custom Mold Design Service
Our mold design provides complete mold design solutions for processes such as injection molding and blow molding. It reduces the number of mold trials, ensuring product consistency and stability in production.
Booling: High-Precision Automotive Lamp Molds for NEV Makers
With over a decade of experience in precision mold manufacturing, Booling Mold has developed automotive lamp molds for a leading new energy vehicle manufacturer and established itself as one of its qualified suppliers. This collaboration focuses on delivering complex lamp molds and injection-molded components, fully complying with the client’s stringent requirements for lamp light distribution performance, surface finish and mass production efficiency.
Challenges And Difficulties
Precision Requirements
The vehicle models of this automaker are equipped with matrix LED headlamps and full-width taillights, featuring intricate light guides. The molds adopt ultra-high gloss polishing (SPI A1 grade) and precise optical geometry processing, to ensure even light distribution without dark spots or bright lines.
Multi-Material Molding
The automaker’s lamp assemblies integrate diverse materials including transparent polycarbonate, black housings and chrome trims into one unified component. The production demands advanced multi-station injection molds, alongside precise rotary and core retraction mechanisms.
High-Volume Production
The automaker achieves a monthly output of tens of thousands of vehicle units or more. The dimensional accuracy is required to remain consistent across all production runs.
Short Development Cycle
Mold development, try‑out, and optimization must be completed within 45–60 days.
Solutions
Optical Simulation And Mold Design
Booling’s engineering team collaborated with the automaker’s optical designers to conduct mold flow analysis. This optimizes gate locations and cooling channel layouts, minimizes warpage and guarantees optical precision.
High-Precision Mold Manufacturing
Using 5‑axis CNC machining and EDM processes, Booling achieves mold cavity surface roughness below Ra 0.05μm.
Advanced Multi‑Shot Tooling
For combination lamp assemblies, Booling’s multi‑shot molds can produce 2‑color and 3‑color parts in a single cycle, increasing production efficiency by 40% compared to traditional assembly methods.
Mold Lifecycle Traceability
Every piece of core data—ranging from mold steel batches and CNC/EDM machining parameters to try-out and mass production settings—is rigorously recorded. This establishes a complete digital thread from raw materials to mold delivery, and ultimately through to final product manufacturing.
Mold Design Services We Offer
Custom Injection Mold Services
We provide mold design services for injection molds, including gate design, edge gate, hot runner, and more.
Custom Stamping Die Services
We provide mold design services for stamping dies, extending die life and improving material utilization in die manufacturing.
Our Mold Design Process
Product Analysis and DFM Report
At this stage, we can provide customers with feasibility assessments including wall thickness evaluation, draft angle, and undercut analysis.
Mold Structure Concept Design
At this stage, we can determine the parting line, number of cavities, and gate type for the product.
Simulation Verification
At this stage, we can perform cooling analysis, flow analysis, and structural strength verification for the product.
Design Drawings
At this stage, we can provide 2D assembly drawings and 3D mold drawings for the product.
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