The aim of the paper consisted in the development of an injection mold for plastic horn cover parts in commercial vehicles. Three mold types were designed in anticipation of the structure and quality of molds, and injection molding numerical analyses were conducted for the three types of molds. One mold type was selected in consideration of the resin flow patterns inside the mold, surface quality, and final deflection amount of the horn cover. To perform optimal injection molding using the selected mold, optimization of injection molding parameters was performed using the Taguchi method, one of the designs of experiment (DOE) and ANOVA methods. As a result, it was confirmed that the deflection amount of the molding under optimal molding parameters decreased by about 34.3% compared to the deflection amount before optimization of the molding parameters. Based on these encouraging results, the previously selected mold type was actually manufactured. The horn cover was molded using the obtained optimal injection molding parameters to the manufactured mold. To verify the precision of the molded horn cover, the deflection amount of the molding was measured with a 3D scanner. The deflection amount of the horn cover was estimated to be about 11% to 43% larger for each measurement position than the deflection amounts in the analysis results. The manufactured mold was revised to solve the problem that the deflection amount of the actual molding is larger than the deflection amount predicted by injection molding analysis. The dimensions and surface quality of the horn cover with a revised mold were satisfactory.

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