Computer-aided gas-assisted injection-molding of the front cover of motorcycle headlight

In this work the gas-assisted injection molding process in introduced to the manufacture of front cover of a motorcycle headlight in order to replace the traditional metal-made part. Due to the sensitivity of gas flow to the design and process variables, computer-aided engineering (CAE) technique is adopted in the design phase to evaluate the key parameters that may effect the process dynamics and part quality. A special overflow design is used in this case to lead the gas flow. The analysis results are confirmed by experiments conducted in molding trials.