General information of electroform
Taiwan K-Lite is the representative unit of K-Lite Industry, which manage and lead the core of technology. Also, we have our production plants and 8 offices in Taiwan and mainland China.
K-Lite also develops nickel-cobalt casting, the hardness of electroform products can reach more than 45 HRC.
The reflectors: Regardless of the automotive industries, we have more than 500 individual cases of mass production, and also obtain certifications.
For the full range of bicycle reflectors products and Warning Triangle, K-LITE mold core can also reach many specification standards.
Flat electroform 100X100(mm2)
SAE bare match value can reach more than 50000mcd! Our product classification and other grades, provide case evaluation and design consultation, Wire EDM, molding, and mass production services!
Customized curved electroformed cores are also available in 3D CAD.
With scientific simulation and actuarial, accurate Feasibility, once the case confirmed, we promise that the product has passed the regulatory certification!
K-LITE has our own A Class standard light distribution room, based on the experiences of many years optical design, mold and molding, K-LITE is one of the world's few professional suppliers of reflectors with core-making ability.
K-LITE provides the electroforming services, such as manufacture, molding, even the product OEM, a series of supporting services.
REFLEX electroforming casting process
K-LITE has the whole technology of electroforming nail grinding, design, process fixture and BACK-PLATE mold base.
Electroforming Division: Since 2008, it contents PIN's homemade grinding, CLAMP. PIN.PLATIN.BACK-PLATE ...
There are nearly 20 electroforming tanks with RD, and the annual output value is about 800,000 US dollars, and the annual output of flat electroform are about 200 pieces.
Important Aspects of the Production of Reflex Reflector Tooling
The Polishing of the Female Die Cast (reflector side):
Reflectors are considered optical-level product, therefore whether it’s inserted or in any other form, the surface finish and the mirror polishing of the product and outer lens are extremely important.
Cooling Channel Design:
The channels should be close to the electroform and spread as wide and as evenly as possible.
The tooling should have air vents designed into it so to prevent ill-forming product.
General Rule for Reflector Injection Molding
The Thickness of Reflectors:
Reflectors with small surface area: 1-1.3mm thickness
Reflectors with bigger surface area: 1.5-2mm thickness
Conditions for Molding:
Tooling Temperature: over 80ﾟC
Cycle Time: The Pressure should be kept at a certain degree.
Injection Pressure Control: According to the machine, but not too high
Feeder Tube Temperature: according to material
Before and after injection molding, Please use air blow gun to remove any dust or residue on the surface of the electroform. Then, dip a brush into organic solvent(e.g. acetone or cleaning naphtha) and remove all antirust oil properly. Afterwards, examine all the reflect surfaces to see if there are any residue or scratches.
The residue oil will break down the Ni layer and cause oxide that makes the surface uneven and rusty.
Dust and plastic mixture would scratch the surface and decrease the level of reflection.
Our Production Ability – Injection Molding
8 Injection Machines, 24 hours production, 3,000,000 pieces per month.
Our Production Ability – Ultrasound welding
4 ultrasound production line, 80,000 pieces per day
1 automatic ultrasound production line, 20,000 pieces per day
Quality Control Ability
We own the standard equipment to test reflectors and 30.48m standard darkroom.
Regular examination equipment:
Cyclic Corrosion Test, Constant temperature water tank, high and low temperature test, Goniophotometer