Plastic Injection

Our injection capability covers the range of technologies and applications the automotive lighting industry needs. It includes single-, two-, and three-colour injection and the processing of many engineering and polymer materials, so we can produce parts with complex geometry, tight dimensional and functional requirements, and varying levels of complexity.

Alongside general injection moulding, we have dedicated equipment and processes for moulding socket parts, as well as vertical presses. This range lets us meet the needs of the different parts and sub-assemblies in a lighting system.

A specialist capability of this unit is moulding lenses and bezels in cleanrooms. This covers optical parts such as matte cover lenses and light guide lenses. Where needed, lenses and bezels move in-line to finishing processes such as hard coating and metallization, which keeps the production chain connected and reduces handling of sensitive parts.

To finish parts and keep quality repeatable, we also use specialised techniques such as cooling jigs and laser gate cutting.

Our polymer processing is not limited to thermoplastics and BMC. Rubber injection and rubber part production are also done in-house, completing the range of polymer parts we make for automotive lighting systems.

Further along the chain, we produce some of our own protective packaging, including plastic film, bubble wrap, and corrugated plastic board, used to protect, pack, and move parts.

Materials engineering is a core part of our injection infrastructure, covering the engineering, thermoplastic, thermoset, and polymer compounds used in automotive lighting.

The work includes material preparation, compounding, formulation development and modification, and optimising materials for each part's application and process conditions. Because materials engineering sits close to the injection process, we can study how materials behave, develop new solutions, and give technical support to products and production.

In-house formulation capability, especially for BMC, has let us move from buying ready-made materials to engineering materials around the needs of the product and the process.

Our digital production system monitors the process and actual output online and makes process and production data available for engineering analysis and decisions.

Besides key process parameters, it records output, good parts, scrap, and production stoppages online. Stoppage data is used to analyse performance and find room for improvement.

Online SPC (statistical process control) tracks trends in key parameters and flags variation and process drift.

Combining process and production data supports continuous improvement of cycle time, part weight, scrap, energy use, and process stability, and moves us towards data-driven production.

Our quality control and laboratory unit has specialist capability to evaluate raw materials, control the process, and test the properties and performance of polymer and rubber parts.

For material properties and identification, tests include MFI, DSC, and impurity and ash content measured in a furnace. These are used to evaluate raw materials and check them against technical requirements.

For mechanical and functional properties, we run tensile tests, plastic and rubber hardness tests, impact tests at ambient and low temperature, and Charpy and Izod tests. Abrasion and rub tests assess the wear resistance and durability of materials and parts.

Thermal behaviour is assessed with HDT and Vicat tests, along with heat and humidity tests.

These tests are used in raw material approval, product development, process validation, production control, failure analysis, and continuous improvement, and they tie directly into materials engineering and the injection process.

Laboratory work follows ISO/IEC 17025, and the quality management system is organised to IATF 16949. The group also works within its technical cooperation with the Iranian National Standards Organization.