Interior LED Lamp Manufacturing Process Overview

This is a manufacturing case for Interior LED Lamps, covering the entire process from product design, material selection, and tooling production to injection molding, assembly, and quality control. Efficient communication and rigorous quality checks ensure the product's high quality and timely delivery.

original source: https://firstmold.com/case-study/lamp-component-parts/

materials: ABS

types of manufacturing: plastic injection molding service and injection mold making service

The Interior LED Lamp, designed for use in car compartments, is made from a combination of plastic and aluminum materials. The production process integrates plastic molding and die-casting techniques. In this case, we will focus on two key components: the Reflector and the Lens.

The client initially approached us with a request for tooling products related to the LED Lamp, needing a quantity of 1,000 units for their marketing purposes. Our sales team responded with a quote within 12 hours, adhering to our standard production tooling quote timeline. For simpler structures and rapid tooling, we can expedite the process to as little as 6 hours, minimizing our clients' wait time and giving them more time for evaluation.

After swift communication, we agreed on the materials: LG CHEM LUPOY RF3208 solid white for the housing and Bayer Makrolon PC2647 clear for the lens. The RF3208 material offers excellent transparency, making it ideal for use in LED lamps, and provides high temperature and wear resistance. These material choices were based on the client's design specifications and recommendations from our CAD engineers.

We then proceeded to the Design for Manufacturing (DFM) phase.

Typically, the DFM process is completed within 1 to 2 days. After reviewing the 3D model, we began the DFM analysis to propose a design solution to the client. This will serve as the foundation for tooling design.

Once the design was finalized, we proceeded with the injection molding of the parts and conducted initial tests. Based on the results, adjustments were made to the tooling to ensure high-quality parts were produced.

The assembly process includes the following steps:

1. Gathering accessory parts
2. Installing the O-ring
3. Installing the PCB
4. Assembling the light cup
5. Installing the light cup
6. Applying glue
7. Final assembly completed

Our Quality Control (QC) department is proud to be recognized as a trusted supplier. All parts undergo rigorous inspection to ensure perfection. We check every detail against the 3D model and ensure all dimensions are within the specified tolerances. Our quality checks include a series of dimensional measurements, lighting tests, sealing tests, and more to guarantee the product meets the highest standards.