Reflex tooling inserts from Urgent Plastics Services help form production-quality "real-life" surface finish for prototype manufacturers of automotive lens components.
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Urgent Plastics Services, a specialist in the rapid prototyping of injection-molded plastic components, has been developing a process to provide prototype lighting components more quickly for new production and concept vehicles. According to Jeffrey Peterson, General Manager, the company is able to render 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 provides vehicle stylists and engineers with the time and cost advantages to review and modify 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," said Peterson. "This approximated the cosmetic 'look' of the lens, but not the required reflectivity. Making the reflex tooling insert is a long and labor intensive process, taking anywhere from 16 to 18 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."
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 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," claimed Steve Kelly, Senior Sales Engineer. "Our time savings is generated during the electroforming step."
While the specialty tool house is creating the reflex inserts, Urgent Plastics Services is designing the balance of the required tooling based on the customer's CAD data file, building the molds, and injection molding the parts - lenses, housings, and, if required, any styling overlays. The company has produced several taillamp assemblies and rear window brake light packages, while headlamp system development is 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 stated. "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 assure safety guidelines are met."
Kevin Jost
AEI September 2000
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