Electric Bicycle Headlight Pad Printing Machine: TEFISEN's Cost-effective Solution

【Abstract】The "Global Electric Bicycle Market Research Report" clearly shows that in recent years, the global electric bicycle market has experienced explosive growth, and its development momentum is extremely remarkable. It is predicted that by 2025, the global electric bicycle market size will successfully exceed the threshold of 30 billion US dollars. As an important component of electric bicycles, the irregular oval shell of the headlight poses many challenges for printing. let's see how TEFISEN solves these problems.

I. The Electric Bicycle Market

Looking back at 2021, the global electric bicycle market size was approximately 17 billion US dollars. In just a few years, it is expected that by 2025, this figure will soar to 30 billion US dollars, with a compound annual growth rate (CAGR) as high as 12.9%. In terms of market regional distribution, the Asia-Pacific region has become the core market for electric bicycles. In particular, China and Europe play a dominant role. Among them, the Chinese market is the mainstay in the global electric bicycle market, accounting for approximately 60% of the main share, fully demonstrating its important position in the global market.

Focusing on the Chinese market, as the largest electric bicycle market in the world, its scale is astonishing. In 2023, the scale of the Chinese electric bicycle market was approaching 100 billion yuan, demonstrating strong market vitality. In terms of sales volume, the achievements are also remarkable. In 2023, the annual sales volume of electric bicycles in the Chinese market was close to 35 million units, and the growth momentum is strong. It is expected that by 2025, the annual sales volume will reach 40 million units, maintaining a steady growth trend.

Among the many key components of electric bicycles, the headlight is undoubtedly an important part. It not only shoulders the important task of providing powerful lighting functions, illuminating the way forward for cyclists, but also plays a key role in appearance decoration, directly affecting the overall aesthetics of the electric bicycle. At the same time, facing the complex outdoor usage environment, the headlight also needs to have excellent wear resistance. However, when it comes to printing on the irregular oval shell of the headlight, many problems arise one after another.

II. The Difficulties in Printing Oval Products of Electric Bicycle Headlights

When it comes to the printing of electric bicycle headlights, it is really a headache. The biggest trouble lies in its irregular oval appearance. Customers even require relevant content to be printed on the inner periphery of this oval shape, which has stumped many people.

Let's think about it carefully. There are many issues to consider:

1. The shape is too tricky, and printing is extremely difficult: It is extremely difficult to carry out printing inside the irregular oval shape of the headlight. Its curved surface is like a naughty child that doesn't obey at all. This leads to inaccurate positioning, and the ink cannot be evenly covered as desired. It's like painting on a bumpy spherical surface. Trying to paint it neatly and beautifully is almost as difficult as ascending to the sky.

2. The ink adhesion is a concern: Most electric bicycle headlights are made of PC material, and the surface of this material is as smooth as a mirror. Therefore, whether the ink can adhere firmly to it is a major issue that must be considered. If the adhesion is not good, the printed content will fall off in a few days, or it will be wiped off easily, which would be extremely embarrassing, and customers will definitely not be satisfied.

3. The ink leveling property needs to keep up: During the printing process, the oval surface has high requirements for the ink. Ink with good leveling properties is required. Otherwise, the printed content will have pockmarks or be uneven, looking extremely unsightly. It's like painting a wall. If the paint does not level properly, the wall will be pitted and not beautiful at all.

4. The pad printing rubber pad must be reliable: The pad printing rubber pad is also crucial. It needs to be able to clearly transfer the content to be printed onto the product. Moreover, it must completely expel all the air inside. If the air is not completely expelled, the printed product will have bubbles or an incomplete pattern, which would be a waste of effort.

III. The Solution of TEFISEN TFS-CP1-200 Pad Printing Machine

As mentioned before, there are many difficulties in the printing of electric bicycle headlights. However, the TEFISEN TFS-CP1-200 single-color pad printing machine is like a super savior and has become an excellent choice for printing on the oval headlight shells. The design and technical advantages of the TFS-CP1-200 are specifically aimed at solving the printing problems of irregularly shaped products, almost "tailor-made" for them.

1. The Unique Advantages of TEFISEN TFS-CP1-200

It uses PLC microcomputer control, which is like having a smart little brain. The positioning is extremely accurate, and the machine runs stably without any "shaking". Its printing area can reach φ120mm, which is just the right size for products like electric bicycle headlights. Moreover, the pad printing steel plate it uses is made of imported material with a size of 150 x 300mm, and the quality is excellent. The height of the object that can be printed should not exceed 300mm, and for products with the size of headlights, there is no problem at all. It works at an astonishing speed, capable of printing 1,500 pieces per hour, with extremely high efficiency.

2. The Ingenious Method of Two-step Printing

Because the headlight is oval and has a special shape, a method of two-step printing has been devised. This is done to ensure that the printed pattern is complete and the ink can adhere firmly. The first time, print the large-area background color or base color, just like laying a base color for painting; the second time, print the detailed patterns or text. In this way, the problem of uneven ink application is solved, and the finally printed pattern is clear and beautiful.

3. The Advantages of TEFISEN TS100 Series Ink

The headlight shell is generally made of PC plastic, and the surface is slippery, which requires high adhesion of the ink. The TEFISEN TS100 series ink is very powerful. It has strong adhesion and is particularly wear-resistant. Its leveling property is also very good, and it is evenly applied without being uneven. In addition, it can withstand high temperatures. In a high-temperature or outdoor environment, the printed pattern can remain unchanged for a long time, always looking beautiful, and the quality is highly guaranteed.

4. The Ingenious Design of the Double-headed Pad Printing Rubber Pad

The TEFISEN TFS-CP1-200 pad printing machine is also equipped with a double-headed pad printing rubber pad, which is a very clever design. Especially when two-step printing is required, it can greatly improve the printing speed, save a lot of time, and ensure the printing accuracy. It will not result in poor printing quality just because of the high speed. It is truly both fast and good.

IV. The Real Feedback from Customers after Use

Let's talk about the feedback from customers. The customers have been deeply involved in the electric bicycle industry for many years. They have extremely strict requirements for product appearance design and production technology, especially in the design and printing of electric bicycle headlights, they are not sloppy at all.

After using the TEFISEN TFS-CP1-200 pad printing machine and the TS100 series ink, the effect is excellent. The following is the real feedback from customers on this equipment and technology:

The printing quality has greatly improved: The two-step printing process has achieved good results. The patterns on the headlight shell are clear, and the colors are rich. There are no troublesome situations such as poor ink leveling, pockmarks, or unevenness. The adhesion of the TS100 series ink is also good, ensuring that the patterns remain stable for a long time without falling off or fading easily.

The production efficiency has significantly increased: The TFS-CP1-200 pad printing machine is convenient for automated operation, and the printing technology is accurate, which has been a great help to the customers. The production efficiency has increased suddenly, and the production cycle has been shortened by more than 20%, which is a significant improvement in efficiency.

The customer satisfaction has soared: After this improvement, the customers are very satisfied with the quality, efficiency, etc. of the produced headlights, and we have also gained a loyal fan.

Therefore, from the usage situation of customers, it can be seen that the TEFISEN TFS-CP1-200 single-color pad printing machine and the TS100 series ink have really been of great help, successfully solving various problems in the printing process of electric bicycle headlights. Especially when printing on the irregular oval shell, the high precision of the equipment and the excellent adhesion of the ink are fully demonstrated.