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How to make LED lamp by injection molding?

1. Mold Design:

Initially, a mold must be designed and fabricated to shape the LED lamp. This mold generally has two parts: a fixed part (the stationary mold) and a movable part (the moving mold). The shape of the cavity within the mold dictates the final shape of the LED lamp after the injection molding process.

2. Material Preparation:

  • Appropriate plastic materials are chosen, typically transparent or semi-transparent plastics like polycarbonate (PC) or polymethyl methacrylate (PMMA), due to their excellent optical properties and durability.
  • Plastic pellets are fed into the hopper of the injection molding machine, where they are heated to a molten state by the machine’s heaters.

3. Injection Process:

The molten plastic is injected into the mold cavity through a process that includes four main stages: injection, holding pressure, cooling, and mold opening.

  • Injection Stage: The screw mechanism pushes the molten plastic into the mold cavity.
  • Holding Pressure Stage: Once the cavity is filled, pressure is maintained to ensure the material is completely filled and to prevent shrinkage.
  • Cooling Stage: The plastic cools and solidifies inside the mold, typically assisted by the mold’s cooling system, such as water channels.
  • Mold Opening Stage: The mold is opened, and the molded LED lamp housing is ejected.

4. Post-Processing:

  • The LED buld removed from the mold may require post-processing tasks such as deburring, inspection, and trimming.
  • Additional processing might be necessary, such as printing patterns on the housing or attaching other components.

Through this process, LED lamp housings can be mass-produced efficiently, ensuring dimensional precision and surface quality. Injection molding is a highly efficient manufacturing method, especially suitable for producing complex shapes and large volumes of plastic products.

LED injection molding machine
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