Abstract
This paper investigates the mold design and related effects on an aspheric projector lens for Head Up Display (HUD) with injection molding process. Injection flow analysis with a commercial software, Moldex3D has been used to simulate this projector lens for filling, packing, shrinkage, and flow-induced residual stress. This projector lens contains of variant thickness due to different aspheric design on both surfaces. Defects may be induced as the melt front from the gate into the cavity with jet-flow phenomenon, short shot, weld line, and even shrinkage. Thus, this paper performs a gate design to find the significant parameters including injection velocity, melt temperature, and mold temperature. After simulation by the Moldex3D, gate design for the final assembly of Head Up Display (HUD) has been obtained and then experimental tests have been proceeded for verification of short-shot, weight variation, and flow-induced stress. Moreover, warpage analysis of the Head Up Display (HUD) can be integrated with the optical design specification in future work.
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