Abstract: A method of manufacturing an automotive reflector comprising a series of steps. A thin plastic film having a backing material is thermoformed into the rough shape of the reflector. The thermoformed film is called a pre-form. The pre-form has a concave surface and a convex surface. The backing material forms the convex surface. The pre-form is placed within an injection molding press with the concave surface juxtaposed a mold core. Molten reinforced plastic material is injected into the mold adjacent to the backing material. The plastic material heats and fuses to the backing material to form a reflector. After the plastic material has cooled, the reflector is removed from the injection mold as a finished reflector.

Abstract: A plastic joint for an automotive lamp assembly (10) has a housing (14) containing a tongue (20) and lens (12) containing a groove (18) to accept the tongue. The tongue or the groove can provide a channel for a thermoplastic material that is a bonding agent between the tongue and groove. The channel can also be formed by making the tongue narrower than the groove or by providing protrusions or depressions on the tongue or groove. The joint is formed by assembling the housing and lens and injecting the thermoplastic material into the channel in the joint. When the thermoplastic material cools, a bond is formed between the tongue and groove that fastens the lens and housing together.