Press Release
TAKING A SHINE TO LIGHTING PROTOTYPES, WITH REAL REFLEX
Reflex tooling inserts help form production-quality "real life" surface finish for prototype manufacture of automotive lens components.
Vehicle prototype lighting lenses now provided with production-like optical pattern reflective surfaces with low-cost, low- risk tooling…in six weeks, not four months
ROCHESTER HILLS, Michigan — For some time, Urgent Plastics Services (UPS), located here and a specialist in the rapid prototyping of injection molded plastic components, has been working with automakers to provide prototype lighting components for new models and concept cars, SUVs and trucks. Now, according to Jeffrey Peterson, General Manager, the company is able to render those lenses with actual, production-quality reflex tooling inserts in one quarter the normal time and at a fraction of the costs associated with production tooling. This capability allows vehicle stylists and engineers the time and economics to thoroughly review and modify, if necessary, designs prior to making long term, high-cost mold and tooling commitments.
"In the past, we've simulated the reflex pattern—those areas of the lenses that reflect outside light sources—using a multi-axis drill pointing process when making the injection molds," says Peterson. "This approximated the cosmetic 'look' of the lens, but not the reflectivity required. Making the reflex tooling insert is a long and labor intensive process, taking anywhere from 16 to18 weeks to complete. Now, working with a reflex tooling specialist, we're getting these inserts—real reflex optical patterns—in about six weeks. The time savings also results in substantial cost reductions that make prototype styling reviews possible, and promote 'healthy' production tool manufacturing."
Steve Kelly, Senior Sales Engineer, explained the process of making a reflex insert for the injection molding process:
The insert begins as hundreds of individual pins, the ends of which are ground to the required geometric shape, nickel plated and diamond polished to a mirror finish. The pins are then assembled into bundles, creating a “positive” image of the size, shape and surface contour of the reflex area. Once completed, the bundle is used in an electroforming process where an alloy deposition builds up on the bundle form until it is the required thickness. When removed from the pin bundle, the deposited alloy piece is machined to fit in the injection mold and thus, the reflex insert is made.
"The machining of the pins, the assembly of the bundle and the quality of surface finishes for the prototype tools are the same as for production tools," claims Kelly. "Our time savings is generated during the electroforming step."
While the specialty tool house is creating the reflex inserts, UPS is designing the balance of the required tooling based on the customer's CAD data file, building the molds, and the injection molding of the parts—lenses, housings and, if required, any styling overlays.
Thus far, the company has produced several taillamp assemblies and rear window brake light packages, while headlamp systems are currently underway. The completed projects, in both acrylic and polycarbonate materials, have included wrap-around side light designs, and multi-color inlay lenses to differentiate brake, turn signal, and backup lighting.
"Government regulations dictate what level of reflectivity and visibility is on cars," Kelly states. "As designers and stylists come up with new and exciting concepts for vehicles, it's becoming more important that they know—before expensive tooling is made—that their designs follow those reflective requirements. Real reflex inserts and rapid prototype processes are helping to eliminate long delays, high-risk costs, and to assure safety guidelines are met."
UPS was established to meet the needs of the plastic parts manufacturing industry, and specializes in the rapid prototyping of injection molded components. Its list of capabilities includes a fully equipped in-house mold and pattern shop, a carbide machining and grinding center for the production of EDM tooling, an array of ram type die-sink and wire EDM systems, plus CNC and manual machining centers and milling machines. The prototype facility also boasts its own injection molding department, with machine capacities from 75 tons to 1500 tons. UPS also has at its disposal a vast selection of rapid modeling systems, among which are stereolithography systems, allowing the firm to fabricate and provide its clients with physical, three dimensional replicas of parts within a few hours, before any tooling is started.
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