Automotive Plastic Injection Molding: Dual-Color Taillight Mold Development
Published On: September 7, 2026
As an experienced automotive injection molding supplier, our engineering team developed a precision two-shot tooling solution for a dual-color (red + clear) taillight lens. Leveraging advanced automotive plastic injection molding capabilities, this case demonstrates our ability to deliver reliable, high-precision production for automotive lighting components.
Engineering Challenges
Optical Clarity: Minimizing air traps, weld lines, and sink marks within transparent PC/PMMA zones to satisfy visual and photometric quality requirements.
Interface Precision: Managing volumetric shrinkage differences across materials to prevent flash, bleed, and boundary sealing failure at the dual-color interface.
Warpage Control: Mitigating cooling-induced thermal deformation across complex curved geometries.
Technical Approach
Thermal & Warpage Analysis: Utilizing Moldflow (CAE) simulation to optimize gate positions and cooling layouts, ensuring balanced thermal dissipation and minimal part distortion.
Optical-Grade Machining: Utilizing high-grade mold steel (e.g., ESR S136) paired with high-precision mirror polishing to achieve high optical transmittance.
Precision Sealing Tooling: Engineering multi-stage shut-off faces and tight clamping tolerances to establish clean boundary transitions without flash.
Validation & Outcome
The tooling solution successfully passed rigorous performance validations, including environmental durability, sealing integrity, and basic photometric testing. All key technical specifications meet industry standards, enabling stable and efficient mass production.
