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We wouldn't be able to ultrasonic-weld the lenses to the backing plate if there were LEDs placed closer to the edges.

Nick C.
That's too bad, they would be a great improvement over the ones in the images you have so far. Maybe altering the direction of the film would make it easier for you to do rather than placing it flat in the backing plate, it could have mulit tiered angled areas for each row and improve the look and utility and still be able to be closed with the method you have chosen, or another method of sealing the unit might be your answer. Heat staking is superior to ultrasonic welding today and might allow you to improve your product if you chose to upgrade to more modern equipment.

Historically, plastic assembly projects have always relied on the most reliable, repeatable, and consistent method of joining plastic parts available to them. Half a century ago, this meant using ultrasonic welding tools which at the time seemed like a sci-fi welding solution of unlimited potential.

Heat staking machines, on the other hand, were largely seen as inconsistent machines best used for installing metal inserts in to plastic bosses or housings. However, the forward march of technology continues unabated, and heat staking has taken strides in new directions beyond what ultrasonic welding machines are capable of.

One of the most obvious reasons for this is that heat and plastic technology has advanced a great deal since the 1970s. New polymers respond more precisely to heat, which is more accurately controlled by modern temperature controls and more advanced thermal head systems – our entire industry’s understanding of plastic thermodynamics has vastly increased.

So why isn’t heat staking a more popular plastic assembly method today? The truth is, it is, but only for companies who share a demonstrated commitment to adopting modern approaches and – importantly – phasing out obsolete production methods.
 

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Discussion Starter · #24 ·


Our LED Sidemarkers for the 2010-2014 S197 and 2015-2019 S550 Mustangs are in-stock and ready to ship! Featuring a full strip of high-power LEDs and OEM-grade retroreflector optics, these are perfect for a clean, custom look.

And best of all, we design our LED Sidemarkers using OEM CAD data for perfect fitment right out of the box.

Don't forget to shoot us a PM for free USPS shipping on any U.S order!

Image courtesy of Chrisrgonzales & Whippled_gt (Instagram).

Jake H.
Diode Dynamics

 

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Discussion Starter · #27 ·

LAST CHANCE TO SAVE!!! Until 11:59 p.m. CST on 12/2/2019, you can use coupon code "BLACKFRIDAY" at checkout for 20% off your entire order of lighting upgrades, including our NEW SS3 LED Pods!!! Don't wait, this sale ends TONIGHT!


Jake H.
Diode Dynamics

Sale ends 11:59 p.m. CST on Monday 12/2/2019. Cannot be combined with other coupon codes.
 

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Discussion Starter · #28 ·

Our Memorial Day sale starts NOW! Today through Friday, 5/29/2020, save 20% on all LED upgrades, including our LED Sidemarkers by entering coupon code "USA20" at checkout!


Collin
Diode Dynamics

Sale ends 11:59 p.m. CST on Friday, 5/29/2020. Cannot be combined with other coupon codes.
 

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Discussion Starter · #29 ·

There's no better time to upgrade! Through Friday, 5/29/2020, get 20% off all our LED upgrades for your ride, including our LED Sidemarkers with coupon code "USA20" at checkout!


Collin
Diode Dynamics

Sale ends 11:59 p.m. CST on Friday, 5/29/2020. Cannot be combined with other coupon codes.​
 

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Discussion Starter · #30 ·
Light Amber Tableware Automotive lighting Gadget


TWO YEARS of non-stop stress testing!

This includes vibrations tests, extreme temperatures (hot and cold), pressured water, corrosion testing, and more.

Our LED Sidemarkers were designed and built to stand the test of time. And they're backed with a 3-year warranty!

Just a reminder, all forum members are eligible for a free US shipping code. Just send us a direct message for the code.

John C.
Diode Dynamics
 
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