Current) New Technology
Prototype development for press processing of focus curved reflectors for automotive lighting lamps
Cost, up to approx. 20% reduction!
Quality/performance, approx. 20% improvement!
Mass, approx. 10% reduction!
Purpose of development
the current light distribution functional component "reflector" used is
Mainly manufactured by die-casting, but
the high cost and weight load due to material thickness
results in a low yield of high-brightness processing (aluminum evaporation);
this low productivity has become an issue, and lamp manufacturers
need a new manufacturing method.
Therefore, we apply deep drawing technology,
to make complex 3D shapes such as reflectors
through a manufacturing technology using press processing we have developed.
Effect of development
Reflectors are usually made of die-cast aluminum, but due to the processing characteristics, small holes
called "pinholes" may occur in large quantities. The defect rate is high, and the board thickness limit of 2 mm
has been considered unsuitable for weight reduction. By combining deep drawing technology and 3D measurement technology,
In the case of press processing that has been realized, the defect rate is low, the yield rate is dramatically improved, and
the board thickness can be reduced to around 0.6 mm, making it possible to significantly reduce weight.
Comparison with conventional products (die-cast processed products)
Regarding this developed technology
We also have materials related to this prototype development product.