The use of injection molding for street bikes

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Have you ever wondered how many components a street bike consists of?

It is a question that I asked myself but to which I have not found an answer.

Surely it is a product that over the years has evolved a lot from every point of view.

Design is increasingly sought after to meet the unbridled needs of its customers; the study of the small details is more careful to give shape to a captivating, unique product with amazing performances.

Each component of the bike has its own history and follows a customized development: the study of design, engineering, prototyping and mass production.

In this article we will tell you some details of the development of the front light assembly cover of the Moto Morini CORSARO ZZ vehicle.

Plastic molding for headlights

The study of this bike with a classic shape and modern technique, has focused on performance at the wheel to give an exciting, fast and sporty ride as well as precise and safe.

The design of the headlight assembly

The layout of the optical unit has been entirely studied and designed by Moto Morini Srl, a leading company in the production of motorcycles since 1937.

The study and design of every single detail of the new headlight follows the image that the Corsaro has always given of itself but now, on the ZZ model, it uses two LED headlights with the dual high / low beam function. Same LED technology also for the position light, rear light, and direction indicators of the bike

The component was developed to be produced via injection molding.

Production from plastic molding

Before moving on to mass production from plastic molding, it is necessary to engineer all the files that make up the product and adapt them to the production process.

Having received the files suitable for the production of the steel mold, we evaluated the feasibility of production by injection molding with PA6 + GF30% material: polyamide (nylon) reinforced with 30% with glass filler to reinforce the mechanical resistance and obtain greater rigidity and dimensional stability. The request provided for the co-molding of the inserts provided on the piece with the material.

The mold was designed by our engineering team to guarantee the performance and technical specifications of the project: mold with cold runner on the piece, mold holder material 1.173, cavity material 1.2344, predisposition for metal inserts, mold life guaranteed 50.000 cycles, cooling system on the mold and the possibility of molding with a standard or embossed finish.

Once the equipment has been produced, a first production of a few units is always envisaged to validate the production.

Following the validation, and having shared all the notes on the first production, we have started the definitive production for the entire lot.

The whole process from the start of the project to the final production of the molding pieces was completed in about 9 weeks

The production from injection molding to the rear instrumentation of SCRAMBLER.

With the same production process we have created the rear-instrumentation of the Moto Morini SCRAMBLER model

Injection molding is the most used technology in the industrial field for the production of plastic parts.

Our experience is mainly focused on mold making and short run molding. Specifically, we can make molds in aluminum or tempered steel with the possibility of printing with molding presses up to 1000 tons.

Alternatively, for finished batches in which the project requires a finite number of pieces, we can set up prototype mold equipment to meet all the needs where there is a need to have a pre-series with the final production material.

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