BAOLAIHUA

PRECISIONMANUFACTURING

Home Home

Capabilities Capabilities

Products Products

Materials Materials

About Us About Us

News News

Contact Contact

GET A QUOTE

BAOLAIHUAPrecision Manufacturing Get a Quote

Automotive Horn Cover Injection Mold

Tooling for automotive horn covers and speaker grilles. 1x2 cavity hot runner mold with valve-gate nozzles and EDM-machined micro-perforated inserts in NAK80 and S136, for PC/ABS and PMMA.

Select the number of specifications

Please check the product information you want!

ProductDetail

Injection Molding · Automotive

Automotive Horn Cover
Injection Mold

Tooling for automotive horn covers and speaker grilles. A 1×2 cavity hot runner mold with valve-gate nozzles, EDM-machined micro-perforated inserts in NAK80 and S136, built for PC/ABS and PMMA on our 50T–3000T press range.

Automotive horn cover with micro-perforated speaker grille produced by BAOLAIHUA injection mold

Core & Cavity Steel

NAK80 / S136

HRC 38 texture, HRC 50 mirror

Resin

PC/ABS

0.5% shrinkage, PMMA also

Hot Runner

Valve Gate

Sequenced multi-nozzle control

Cavity Layout

1 × 2

Set by volume at DFM

Overview

A Tool That Holds a Gloss Surface Through a Field of Micro-Holes

An automotive horn cover has to do two things that pull against each other. It is a visible exterior part, so the face has to hold a uniform high-gloss or fine grain finish with no weld line or sink mark crossing it. At the same time, the grille is a continuous field of hundreds of small perforations, and every one of them is a potential air trap that burns, or a stress concentration that cracks in service.

The tool is built for exactly that combination. The grille is not an assembled mesh bonded to a frame; it is moulded in a single shot, with the perforations cut directly into the cavity insert by EDM. Slide cores form the perimeter draft of the housing, and the horn boss is released by inclined lifters, so the part leaves the tool without stress whitening around the holes.

The valve-gate hot runner is what keeps the face clean. A needle valve closes the gate immediately after injection, which removes the stringing and drool an open nozzle leaves on a visible part, and the melt front can be sequenced so the weld line is pushed away from the grille face. The lower internal pressure also reduces warpage and extends tool life.

01

Perforation as a moulded feature

The grille is cut into the cavity by EDM rather than added as a bonded mesh, so there is no secondary assembly step, no adhesive line and no risk of the mesh delaminating after years of horn vibration.

02

Vented micro-holes

Air trapped in each perforation is the classic cause of burn marks on a thin grille. The insert is vented so the holes fill cleanly, and the ejector pins double as vents in the deep corners of the part.

03

Slides and lifters, not a static core

The housing perimeter is drafted by slide cores with hardened wear plates, and the horn boss is pushed off by inclined lifters with bronze guide blocks, so the tool releases cleanly and repeatably.

Part & Tool

From Finished Cover to Production Mold

The parts and the tooling are shown together, so you can judge the grille pattern, the gloss level and the surface continuity before the steel is cut.

Front view of automotive horn cover with hexagonal micro-perforated speaker grille — **Front View — Grille Face**Micro-perforated grille with the horn aperture behind it, in a high-gloss housing.

Angled View — ProfileThe slim section and the wrap of the grille around the housing edge.

Horn cover injection mold cavity side with two square cavity inserts and slide cores — **Cavity Side**Two cavity inserts, with the slide and lifter components that form the housing perimeter and horn boss.

Horn cover injection mold top view with guide posts, hot runner and a 1x2 cavity layout — **Full Tool Assembly**1×2 cavity layout with hot runner, guide posts, guide bushes and the ejection system.

Product Material

Resins We Tool for Automotive Horn Covers

The resin decides the gloss, the impact behaviour and the steel. These are the grades we run most often on this part.

Primary: PC/ABSThe standard resin for a gloss automotive cover

Grade	PC/ABS injection grade, textured or high-gloss
Shrinkage rate	`0.5%` standard, 3.5–4.5 /1000 on large panels
Why it is used	Combines the impact and heat resistance of polycarbonate with the surface quality of ABS, and takes a fine texture or a high polish cleanly
Wall thickness	1.5–2.5 mm over the grille, thicker at the horn boss and mounting ribs
Shrinkage compensation	Cavity and core dimensioned at `part size × shrinkage rate`; mold tolerance set at 50% of product tolerance
Finish	VDI texture, high gloss, mirror or piano black; clear-coat and matte options

Alternatives: PMMA and ABSClear lens covers and cost-driven programmes

Grade	PMMA for a clear lens-type cover; ABS for standard painted or textured parts
Shrinkage rate	`0.5%` for both PMMA and ABS
Why it is used	PMMA gives optical clarity for a lens cover; ABS is the cost-effective choice where the part is painted or textured and does not need polycarbonate impact performance
Tooling note	PMMA and ABS are amorphous and mould well, but the cavity must be vented carefully; PMMA is more sensitive to sharp corners and needs generous radii
Wall thickness	1.5–2.5 mm over the grille
Also available	ASA, PC/ABS at different gloss levels, and textured grades quoted on request

Resin change is a design change. Moving from PC/ABS to PMMA or ABS alters the shrinkage, the cooling requirement and the recommended mold steel — and for PMMA the polish standard on the tool has to be higher. Give us the exact grade and supplier at quotation stage and we will tool for it from the start.

Mold Steel

Mold Steel Specification for This Tool

Steel selection follows the resin and the finish you need on the visible face. The grades below are our standard choice for automotive horn covers.

Mold component	Steel	Hardness	Heat treatment	Why it is specified
Cavity inserts — texture finish	`NAK80` (or `718H` on request)	HRC 38±2 / HRC 36±2	Pre-hardened, no further heat treatment	Polishes easily and resists weld lines on PC/ABS. Pre-hardened steel means the tool can be finished and EDM-cut without the distortion risk of a later hardening pass
Cavity inserts — mirror / high gloss	`S136`	HRC 50±2	Heat treated	Holds a high mirror polish and resists acidic cleaning agents, which is what a visible gloss face needs to stay in specification
Mold base	`P20` / `718H`	HRC 31–38	As supplied	Dimensionally stable plate for the platen and clamping plates, with good machinability for the cooling circuit
Slide cores, angle pins and wear plates	`718H` / `Cr12`	HRC 36±2 / HRC 60±2	Cr12 hardened	The housing perimeter slides on every cycle, so the wear surfaces use hardened Cr12 to protect the mold base from galling
Inclined lifters and ejector pins	`8407` / `SKD61`	HRC 50±2 / HRC 52±2	Hardened	High toughness and heat resistance so the horn boss releases without stress whitening, across a long production run
Bronze guide blocks	CuCr bronze	—	—	Paired with the inclined lifters so the lifter slides without binding, and the part is pushed off without a witness mark
Hot runner manifold and nozzles	Valve-gate (needle valve) system, multi-zone controller	—	—	Needle valve gives a clean gate with no stringing or drool on a visible exterior part, and allows sequenced injection so the weld line can be positioned away from the grille face
Insulation plate	8 mm plate, M6 screws	—	—	Thermal isolation between the hot runner plate and the A plate, dimensioned 4 mm inside the plate edge and locked within the C corner

Other options. 1.2344 (HRC 50±2) for high-temperature grades, 2083 for mirror finish with acid resistance, DC53 (HRC 60±2) for very high-toughness applications, and EM38 (HRC 38±2) as a cost-effective alternative to NAK80.

Specifications

Technical Data

Cavity count, tonnage and cycle time are set against your part and annual volume during the DFM stage.

Application	Automotive horn cover / speaker grille
Category	Injection Molding → Automotive
Product material	PC/ABS (primary), PMMA, ABS; ASA and textured grades on request
Mold core and cavity steel	NAK80 (HRC 38±2) for texture, S136 (HRC 50±2) for mirror finish
Mold base steel	P20 / 718H, with 718H and Cr12 for slide and wear components
Mold type	Hot runner tool with valve-gate nozzles, slide cores and inclined lifters
Cavity layout	1×2 as shown; confirmed at DFM against volume and press size
Runner system	Valve-gate hot runner, no cold slug in the finished part, multi-zone temperature control
Insert technology	EDM micro-perforated cavity, low-current cutting to avoid surface pitting
Grille formation	Micro-perforations formed in a single shot, not an assembled mesh; insert vented to prevent burn marks
Slide mechanism	Housing perimeter drafted by slide cores with hardened Cr12 wear plates and heel blocks
Ejection	Inclined lifters with bronze guide blocks for the horn boss; ejector pins doubled as vents in deep corners
Cooling	Conformal circuits around the grille, with baffle-type channels through the housing wall
Shrinkage compensation	PC/ABS 0.5%, PMMA 0.5%, ABS 0.5%; mold tolerance set at 50% of product tolerance
Surface finish	VDI texture, high gloss, mirror or piano black; 600#–1000# polish available on the cavity
Clamping force	50T–3000T available; press size matched to the cavity layout at quotation
Tool life	Designed for the volume you order, typically 200,000–600,000 shots depending on resin and steel grade
Decoration	Screen printing, in-mold labeling, hot stamping, pad printing and paint
Inspection	Hexagon CMM Global S, accuracy 1.5 µm; full 3D dimensional report before shipment
Certification	ISO 9001:2015, IATF 16949:2016, ISO 13485:2016, AS9100 Rev D

Workflow

From Drawing to Production Tool

Four controlled stages, each with a document you can review before we move to the next.

01

DFM review

We analyze your drawing or sample for wall thickness, draft, parting, shrinkage, ejection and cooling, and return a DFM report with the proposed cavity layout and the machine size.

02

Mold design

3D layout, assembly drawing, core and cavity insert drawings and hot runner routing are issued for your approval before any steel is ordered.

03

Manufacture

Machining, low-current EDM, polishing and assembly on our own CNC equipment, with the full press range available for T0 and T1 trial runs on the actual part.

04

Trial and handover

T0 sample, DFM and T1 confirmation, dimensional report, and a tool review checklist signed off before the mold ships with the spare parts kit.

FAQ

Automotive Horn Cover Mold Questions

The questions buyers most often ask about this tooling before placing an order.

What material is used for an automotive horn cover?−

PC/ABS is the standard resin because it holds a high-gloss or textured surface while absorbing the vibration and impact of a working horn. PMMA is used for a clear lens-type cover and ABS where cost takes priority. All three mould at 0.5% shrinkage.

How are the thousands of grille perforations formed?+

The grille is moulded in a single shot, so the perforations are cut directly into the cavity insert by EDM rather than assembled as a separate mesh. EDM is run at low current to avoid pitting the surface, and the insert is vented so the holes do not trap air and burn.

Why use a valve-gate hot runner on a visible exterior cover?+

A needle valve closes the gate immediately after injection, which removes the stringing and drool an open nozzle leaves on a visible part. Nozzles can also be sequenced so the weld line is positioned away from the grille face, and the lower internal pressure reduces warpage.

Which mold steel suits a mirror finish horn cover?+

S136 at HRC 50 after heat treatment holds a high mirror polish and resists acidic cleaning agents. For a textured or grain finish, NAK80 at HRC 38 pre-hardened polishes easily and resists weld lines on PC/ABS.

What cavity count and machine tonnage does this tool need?+

The tool shown is a 1x2 cavity layout. Cavity count and press tonnage are set against part volume, wall thickness and annual demand during DFM, and the mold is matched to our 50T to 3000T Haitian range.

What documentation is supplied with the mold?+

Every tool ships with a full 3D dimensional report verified on a Hexagon CMM Global S at 1.5 micron accuracy, a tool manufacture review checklist, T0 and T1 trial records and a spare parts kit. We work to IATF 16949 and ISO 9001.

Send Us Your Drawing and Get a Quotation in 24 Hours

Tell us the cover geometry, the resin grade and your annual volume. We will come back with a cavity layout, the recommended press tonnage and a full DFM report, with no obligation to order.

Emailhelp@bao-laihua.com

WhatsApp+86 159 1535 7170

Websitewww.bao-laihua.com

LocationShenzhen, China

No comment

ProductDetail

Injection Molding · Automotive

Automotive Horn Cover
Injection Mold

Core & Cavity Steel

NAK80 / S136

HRC 38 texture, HRC 50 mirror

Resin

PC/ABS

0.5% shrinkage, PMMA also

Hot Runner

Valve Gate

Sequenced multi-nozzle control

Cavity Layout

1 × 2

Set by volume at DFM

Overview

A Tool That Holds a Gloss Surface Through a Field of Micro-Holes

01

Perforation as a moulded feature

02

Vented micro-holes

03

Slides and lifters, not a static core

The housing perimeter is drafted by slide cores with hardened wear plates, and the horn boss is pushed off by inclined lifters with bronze guide blocks, so the tool releases cleanly and repeatably.

Part & Tool

From Finished Cover to Production Mold

The parts and the tooling are shown together, so you can judge the grille pattern, the gloss level and the surface continuity before the steel is cut.

Angled View — ProfileThe slim section and the wrap of the grille around the housing edge.

Product Material

Resins We Tool for Automotive Horn Covers

The resin decides the gloss, the impact behaviour and the steel. These are the grades we run most often on this part.

Primary: PC/ABSThe standard resin for a gloss automotive cover

Grade	PC/ABS injection grade, textured or high-gloss
Shrinkage rate	`0.5%` standard, 3.5–4.5 /1000 on large panels
Why it is used	Combines the impact and heat resistance of polycarbonate with the surface quality of ABS, and takes a fine texture or a high polish cleanly
Wall thickness	1.5–2.5 mm over the grille, thicker at the horn boss and mounting ribs
Shrinkage compensation	Cavity and core dimensioned at `part size × shrinkage rate`; mold tolerance set at 50% of product tolerance
Finish	VDI texture, high gloss, mirror or piano black; clear-coat and matte options

Alternatives: PMMA and ABSClear lens covers and cost-driven programmes

Grade	PMMA for a clear lens-type cover; ABS for standard painted or textured parts
Shrinkage rate	`0.5%` for both PMMA and ABS
Why it is used	PMMA gives optical clarity for a lens cover; ABS is the cost-effective choice where the part is painted or textured and does not need polycarbonate impact performance
Tooling note	PMMA and ABS are amorphous and mould well, but the cavity must be vented carefully; PMMA is more sensitive to sharp corners and needs generous radii
Wall thickness	1.5–2.5 mm over the grille
Also available	ASA, PC/ABS at different gloss levels, and textured grades quoted on request

Mold Steel

Mold Steel Specification for This Tool

Steel selection follows the resin and the finish you need on the visible face. The grades below are our standard choice for automotive horn covers.

Mold component	Steel	Hardness	Heat treatment	Why it is specified
Cavity inserts — texture finish	`NAK80` (or `718H` on request)	HRC 38±2 / HRC 36±2	Pre-hardened, no further heat treatment	Polishes easily and resists weld lines on PC/ABS. Pre-hardened steel means the tool can be finished and EDM-cut without the distortion risk of a later hardening pass
Cavity inserts — mirror / high gloss	`S136`	HRC 50±2	Heat treated	Holds a high mirror polish and resists acidic cleaning agents, which is what a visible gloss face needs to stay in specification
Mold base	`P20` / `718H`	HRC 31–38	As supplied	Dimensionally stable plate for the platen and clamping plates, with good machinability for the cooling circuit
Slide cores, angle pins and wear plates	`718H` / `Cr12`	HRC 36±2 / HRC 60±2	Cr12 hardened	The housing perimeter slides on every cycle, so the wear surfaces use hardened Cr12 to protect the mold base from galling
Inclined lifters and ejector pins	`8407` / `SKD61`	HRC 50±2 / HRC 52±2	Hardened	High toughness and heat resistance so the horn boss releases without stress whitening, across a long production run
Bronze guide blocks	CuCr bronze	—	—	Paired with the inclined lifters so the lifter slides without binding, and the part is pushed off without a witness mark
Hot runner manifold and nozzles	Valve-gate (needle valve) system, multi-zone controller	—	—	Needle valve gives a clean gate with no stringing or drool on a visible exterior part, and allows sequenced injection so the weld line can be positioned away from the grille face
Insulation plate	8 mm plate, M6 screws	—	—	Thermal isolation between the hot runner plate and the A plate, dimensioned 4 mm inside the plate edge and locked within the C corner

Specifications

Technical Data

Cavity count, tonnage and cycle time are set against your part and annual volume during the DFM stage.

Application	Automotive horn cover / speaker grille
Category	Injection Molding → Automotive
Product material	PC/ABS (primary), PMMA, ABS; ASA and textured grades on request
Mold core and cavity steel	NAK80 (HRC 38±2) for texture, S136 (HRC 50±2) for mirror finish
Mold base steel	P20 / 718H, with 718H and Cr12 for slide and wear components
Mold type	Hot runner tool with valve-gate nozzles, slide cores and inclined lifters
Cavity layout	1×2 as shown; confirmed at DFM against volume and press size
Runner system	Valve-gate hot runner, no cold slug in the finished part, multi-zone temperature control
Insert technology	EDM micro-perforated cavity, low-current cutting to avoid surface pitting
Grille formation	Micro-perforations formed in a single shot, not an assembled mesh; insert vented to prevent burn marks
Slide mechanism	Housing perimeter drafted by slide cores with hardened Cr12 wear plates and heel blocks
Ejection	Inclined lifters with bronze guide blocks for the horn boss; ejector pins doubled as vents in deep corners
Cooling	Conformal circuits around the grille, with baffle-type channels through the housing wall
Shrinkage compensation	PC/ABS 0.5%, PMMA 0.5%, ABS 0.5%; mold tolerance set at 50% of product tolerance
Surface finish	VDI texture, high gloss, mirror or piano black; 600#–1000# polish available on the cavity
Clamping force	50T–3000T available; press size matched to the cavity layout at quotation
Tool life	Designed for the volume you order, typically 200,000–600,000 shots depending on resin and steel grade
Decoration	Screen printing, in-mold labeling, hot stamping, pad printing and paint
Inspection	Hexagon CMM Global S, accuracy 1.5 µm; full 3D dimensional report before shipment
Certification	ISO 9001:2015, IATF 16949:2016, ISO 13485:2016, AS9100 Rev D

Workflow

From Drawing to Production Tool

Four controlled stages, each with a document you can review before we move to the next.

01

DFM review

We analyze your drawing or sample for wall thickness, draft, parting, shrinkage, ejection and cooling, and return a DFM report with the proposed cavity layout and the machine size.

02

Mold design

3D layout, assembly drawing, core and cavity insert drawings and hot runner routing are issued for your approval before any steel is ordered.

03

Manufacture

Machining, low-current EDM, polishing and assembly on our own CNC equipment, with the full press range available for T0 and T1 trial runs on the actual part.

04

Trial and handover

T0 sample, DFM and T1 confirmation, dimensional report, and a tool review checklist signed off before the mold ships with the spare parts kit.

FAQ

Automotive Horn Cover Mold Questions

The questions buyers most often ask about this tooling before placing an order.

What material is used for an automotive horn cover?−

How are the thousands of grille perforations formed?+

Why use a valve-gate hot runner on a visible exterior cover?+

Which mold steel suits a mirror finish horn cover?+

What cavity count and machine tonnage does this tool need?+

What documentation is supplied with the mold?+

Send Us Your Drawing and Get a Quotation in 24 Hours

Tell us the cover geometry, the resin grade and your annual volume. We will come back with a cavity layout, the recommended press tonnage and a full DFM report, with no obligation to order.

Emailhelp@bao-laihua.com

WhatsApp+86 159 1535 7170

Websitewww.bao-laihua.com

LocationShenzhen, China

Copy product links

Long by picture save/share

INQUIRY

Онлайн-запрос MORE+

Name *
Work email *
Company *
Requirement *
Submit

Security Code

Refresh the code

Cancel

Confirm

Inquiry Content：

You have no items to require

Add Successfully

Continue To Visit Inquiry Now

No data

Service Center

Baolaihua

Customer service staff

Contacts

TEL

+86 15915357170

Working Hours

MONDAY-FRIDAY

Qrcode

We chat

Whats App

Service Center

Add WeChat friend to learn more about the product

Use Enterprise WeChat
"Scan" to join the group chat

Copy success!

Add WeChat friend to learn more about the product

I see.

Automotive Horn Cover Injection Mold

分享至微信分享

Automotive Horn CoverInjection Mold

A Tool That Holds a Gloss Surface Through a Field of Micro-Holes

Perforation as a moulded feature

Vented micro-holes

Slides and lifters, not a static core

From Finished Cover to Production Mold

Resins We Tool for Automotive Horn Covers

Mold Steel Specification for This Tool

Technical Data

From Drawing to Production Tool

DFM review

Mold design

Manufacture

Trial and handover

Automotive Horn Cover Mold Questions

Send Us Your Drawing and Get a Quotation in 24 Hours

Automotive Horn CoverInjection Mold

A Tool That Holds a Gloss Surface Through a Field of Micro-Holes

Perforation as a moulded feature

Vented micro-holes

Slides and lifters, not a static core

From Finished Cover to Production Mold

Resins We Tool for Automotive Horn Covers

Mold Steel Specification for This Tool

Technical Data

From Drawing to Production Tool

DFM review

Mold design

Manufacture

Trial and handover

Automotive Horn Cover Mold Questions

Send Us Your Drawing and Get a Quotation in 24 Hours

Automotive Horn Cover
Injection Mold

Automotive Horn Cover
Injection Mold