News & Event

The Inglass/HRSFlow mission comprises a non-stop search for innovative solutions to create automotive lamps and lighting with a high quality aesthetic finish. Moreover, the company's realization of the need to pay close attention to customer requirements has led to a new approach which looks to interface with the customer throughout the entire production process, starting from the initial development phase. Preliminary product analysis and the choice of the most suitable production technology and equipment allows customers to reduce cycle time, and minimize any production defects or scrap resulting from the injection process.

The lens for the latest FIAT Bravo is one example among the many molds to have been produced which highlights how this new global approach can bring a wide range of technologies together in order to provide the customer with real added value.

It consists of an inverted mold where the molded piece is extracted at the point of injection and held, during press rotation, by the mold core. Such a process saves 50% of electroformed items due to the fact that they are 'housed' solely in the part of the mold where the red phase injection takes place.

The injection process takes place in two separate steps. First of all, the transparent part is produced by means of skin molding retro injection, a technology that eliminates any visible trace of the injection point. During the second red phase, the plastic is injected directly onto the lens, thus further eliminitating any potential sign of injection. As a general rule, skin molding is normally carried out by a transparent film being overprinted during the first red phase in order to hide the injection point. On the contrary, in the case of the Bravo lens, transparent film molding occurs first of all, and is only then followed by the red phase.

Inglass/HRSFlow employed the DIAMOND LINE hot runner layout to produce this component. Its use of specially adapted materials avoids any risk of polycarbonate 'attacking' the walls of the system, and any resulting unaesthetic spotting which might damage the surface quality and finish of the molded piece. This new range of hot runner systems is especially suitable for any components requiring outstanding surface quality, such as optical applications, display equipment, glazing, automotive lenses, electronic components and lighting.

To sum up, a process and method that focuses on guaranteeing a matchless quality and aesthetic finish for the finished part.