This mold is specially developed for the European supplier's automotive exterior rearview mirror base housing. It is a typical high-demand exterior trim project. Automotive mirror housing integrates complex aerodynamic curved surfaces, Class A appearance textured surfaces, and precision structures for installing sensors such as camera radars. The core challenge is that while ensuring high structural rigidity, the molding warpage in the visible area must be strictly controlled within 0.07 mm, and it must meet long-term outdoor weather resistance requirements.
As a European OEM mold supplier serving the supply chain, JinYi Mold uses the CAE-driven simulation design process as a project standard. This mold completed the full-cycle Moldflow analysis including filling, cooling, pressure-holding and warpage prediction before steel cutting. Risks were pre-locked and the design was optimized through data, ensuring that the mold reached mass production standards in one trial and was successfully delivered and used in European vehicle projects.
Simulated flow channel and cooling system optimization
Highly balanced hot runner:
A four-point sequential valve-controlled hot runner system is adopted. After simulation optimization, the flow path of each gate is balanced, and the material utilization rate reaches 88.89%, reducing stress and warpage caused by uneven filling from the source.
High uniformity cooling:
The mold is designed with a uniform temperature cooling circuit. By adjusting the water path layout and flow rate, the temperature difference on the surface of the mold cavity during the production process is controlled to <3°C. This is a key technical measure to achieve the goal of low warpage injection mold and ensure the gloss consistency of the textured surface.
Mold making
The mold is made of high-hardness, highly polishable steel, and the cavity has undergone precision EDM processing and manual polishing to ensure that the specified leather texture or high-gloss surface can be stably reproduced.
For the sensor mounting holes and buckle structure on the housing, a precise slider and inclined top mechanism are designed to ensure stable movement without affecting the appearance quality.
Process window locking and mass production stability
Based on the simulation results, the core process windows of injection speed, switching point, holding pressure and time were predetermined. Mass production data shows that the process window is robust, the sink mark in the visible area is controlled to ≤0.07mm, and the warpage deformation fully meets the clearance requirements for vehicle assembly.
Quality assurance
We follow the strict standards of European OEMs and perform a complete verification process.
Simulation and physical benchmark verification:
After the mold trial, use a three-dimensional coordinate measuring machine (CMM) to scan the part, compare the actual warpage data with the Moldflow prediction results, verify the accuracy of the simulation model, and use it to guide final process fine-tuning.
Multi-dimensional factory inspection:
The mold passed multiple rounds of mold testing from T0 to T2 before leaving the factory. Delivery documents include: full-size CMM inspection report, material hardness certificate, surface texture inspection sample, and detailed trial mold process parameter records.
Expanded CAE capabilities:
We have successfully applied the CAE methodology proven in this project to the mold development of bumpers, lamp housings, pillar trims and other complex automotive exterior parts, ensuring high quality and low risk across projects.
Delivery service
As a professional automotive mold manufacturer, JinYi Mold not only delivers molds, but also provides full services from feasibility analysis, simulation design, mold manufacturing, domestic mold trial pre-inspection to international logistics support. The success of this set of rearview mirror base molds demonstrates our ability to use precision simulation-driven manufacturing to meet the world's most demanding automotive supply chain requirements.
If you have similar high-appearance, low-tolerance automotive exterior parts mold needs, we can provide engineering solutions based on successful cases. Welcome to contact our engineering team for technical exchanges.
About Us
Jinyi Mold was established in 1998 and is headquartered in Dongguan, Guangdong. Our professional team provides injection mold and die-casting mold services, providing you support in every aspect from design, manufacturing to final assembly.
Production equipment:
dozens of CNC machining centers (gantry & 5-axis), injection molding machines (80-1600 tons), EDM machines, automation equipment, etc.
Scope of services:
Establish solid partnerships with Europe, Australia and Asia to carry out international export business.
Company production capacity: A 13,000㎡ production base in Maoming (built in 2022), backing an annual turnover surpassing 150 million RMB.
Honors and qualifications:
Possess High-Tech Enterprise Certification, ISO9001:2015 Quality management system certification.
Logistics and freight:
Logistics follows international transportation standards, and packaging is packed in reinforced wooden boxes, filled with PE foam and wrapped in moisture-proof bags.
Marketing: Selina Chan
WhatsApp:+8618969686504
Email:selina@jy-mould.com
Contact us to discuss how we can support your project needs
Please know that when you choose Jinyi Mold, we are not only a supplier, but also a Chinese manufacturing partner with 25 years of experience in mold design, manufacturing, and assembly.
