Casting new product-LED headlight heat sink

Innovaw Mechanical has successfully launched a new aluminum die-casting product - the LED headlight heat sink. Designed as a thermal management component for automotive LED headlights, this product is primarily applied in heavy-duty trucks. With an exceptional length of 690mm, this heat sink represents a specially dimensioned product. Innovaw engineers leveraged our technical expertise and flexibly utilized existing equipment to achieve mass production of this extra-long heat sink on a 500T die-casting machine, elimitating the need for the originally specified 800-1000T die-casting equipment requirements. This innovative manufacturing approach has significantly reduced production costs for our clients.

The product adopts high-pressure die-casting and powder coating process, the finished product not only has excellent mechanical properties and good surface accuracy, but also has good corrosion resistance and lightweight features, which fully meets the customer's design objectives, providing a higher performance and more reliable solution for this kind of automotive LED headlight design.

Product Name: LED headlight heat sink
Material: AISI12Cu1(Fe)/ADC12
Finished product weight: 412g
Process: High Pressure Die Casting
Surface requirements: Powder Coating

After receiving the customer's requirements and drawings, our company firstly carries out DFM analysis on the product design to ensure that the product design not only meets the functional requirements, but also reduces the cost, improves the production efficiency and reduces the defects in the manufacturing process.

In the process of analysis, for some of the designs in the customer's drawings, we put forward reasonable opinions and solutions from the production point of view, and finally the customer accepted our opinions and improved them, so that the final product was successfully produced and delivered.

Mold Flow Simulation Analysis

Innovaw's professional engineers conducted a multi-faceted mold flow simulation analysis of the product design to simulate the die casting process from multiple perspectives, including temperature, speed, porosity, and particles.

DFM Communication Process

DFM Communication Process

High Pressure Die Casting Scene

According to the characteristics of the product, the final use of aluminum high-pressure die-casting process, with 500 tons of high-pressure die-casting machine for one-time molding, and ultimately achieve customer satisfaction with the delivery of the finished product!

During the development process, our company strictly follows the APQP process for product development. We adopt SPC to monitor the key parameters in the production process, and fully verify the accuracy and reliability of the measurement system through MSA tools. We combined with FMEA for risk assessment to systematically identify possible potential problems and formulate corresponding preventive and improvement measures Finally, after meeting all the design and manufacturing requirements, we submitted a complete sample for verification through PPAP process to ensure that this aluminum die-casting product meets the customer's quality standards and reaches the requirements for mass production. All products need to pass the whole process inspection, first and last parts, inspection and shipping final inspection. We strive for zero defects and 100% customer satisfaction.