The aluminum die-casting of the LED lamp housing is a die-casting process of the lamp housing. The manufacturing process of the LED lamp housing is made of high-quality aluminum alloy materials through the die-casting process. Aluminum die-casting process is widely used in the manufacture of shells of various LED lamps, including spotlights, downlights, high bay lights, etc.
Aluminum die-cast LED light housing has multiple advantages, making it a mainstream choice for LED lighting products. It mainly has the following advantages:
- Light weight: Aluminum material is a very light weight material, so the LED lamp shell made of aluminum alloy will not increase the overall weight of the lamp, which is very important for the installation and suspension of the lamp.
- Corrosion resistance: Aluminum alloy has excellent corrosion resistance. The environment of LED lamp housing is normally used in a high place, and maintenance is inconvenient. It needs to be able to maintain excellent performance for a long time. The corrosion resistance of aluminum alloy is very suitable. Moreover, many lamps are not used in a good environment. Aluminum alloy die-casting can ensure that the appearance and performance of the lamp can be maintained under various environmental conditions.
- Good heat dissipation performance: The chip of the LED lamp will continuously generate heat during the lighting process. At this time, the shell needs a good heat-conducting material to help effectively dissipate heat. The heat dissipation of aluminum alloy is the best among all metals. Using aluminum alloy to make the LED shell ensures the long-term stability of the LED lamp. This is critical to the lifetime of the LED chip.
- Inexpensive: The cost of aluminum is relatively cheap, which helps to reduce the manufacturing cost of LED luminaires, making them more competitive.
- High plasticity: Aluminum alloy has good plasticity, and can be processed into many complex geometric shapes and designs through die-casting technology, which provides more degrees of freedom for lighting designers.
- Overall, aluminum die-casting for LED light housings is an efficient and reliable manufacturing method that combines light weight, durability, and good heat dissipation, making it ideal for meeting the needs of modern LED lighting products. The wide availability of this material and manufacturing method helps to provide high quality, high performance LED luminaires that meet the requirements of various lighting applications.
Which aluminum material is suitable for LED lamp housing?
The aluminum alloy model of the LED lamp housing is usually selected according to the specific needs and applications of the LED lamp. Our company uses more aluminum models suitable for LED lamp housings, including AA6061 and AA60631. AA6061 and AA6063 have good thermal conductivity and processability, are suitable for extrusion molding, and are widely used in heat sink processing.
The LED lamp shell is generally made of zinc-aluminum alloy, and its conductivity is about 80W/M.K. Many low-power spotlights of 1-3W basically use this process. Its advantages are low production cost and fast production speed, but poor heat dissipation. Aluminum alloy 6063-T5 is generally selected for the aluminum shell of LED energy-saving lamps, and its thermal conductivity is about 180W/M.K. This process is used for the shells of LED energy-saving lamps with higher power. The aluminum of the car can be made more exquisite, and the thickness is easy to control. The heat dissipation surface area will increase, enhancing the heat dissipation effect.
Aluminum die-casting manufacturing steps of LED lamp housing:
At Mindwell, we manufacture aluminum die-cast housings that are widely used in auto parts, lamp housings, mechanical equipment housings and more. Our company has rich experience in the production and manufacture of aluminum die-casting shells. The general manufacturing process is as follows. If there are special design requirements, we need to communicate well in the drawing design. Our engineers will meet the special design requirements according to the needs.
- Melting and pouring: First, the aluminum alloy material is put into a furnace and heated to melting temperature. Once the proper melting point has been reached, the molten aluminum alloy is conveyed into a die casting machine. In a die-casting machine, the aluminum alloy is quickly injected into a pre-designed mold through high pressure. High pressure ensures that the aluminum alloy fills every detail of the mold to guarantee precision and consistency in the final shell.
- Cooling and Solidification: After being injected into the mold, the aluminum alloy starts to cool and solidify. Cooling times generally vary according to the type of aluminum alloy and the size of the case. This step ensures that the shell retains its shape and structure after it has set.
- Mold opening: Once the aluminum alloy is completely solidified, the mold is opened, and the formed LED lamp housing is removed from the mold. This is a critical step to ensure that the casing is undamaged and can be easily removed.
- Subsequent processing: Formed aluminum luminaire housings may have some burrs or rough surfaces. Therefore, the housing is deburred, sanded and cleaned to ensure a smooth finish and meet quality standards. In addition, the housing may be painted or other special coatings to meet design and aesthetic requirements, as required.
- Assembly: The finished aluminum lamp shells are sent to the assembly line to be assembled according to the design drawings. At this stage, components such as electrical components and light sources of LED lights are added to the housing to form a complete LED light fixture.
- Inspection and packaging: After the assembly is completed, the LED lamps undergo a comprehensive inspection and test to ensure that the product quality meets the standard requirements. Once passed inspection, the LED luminaire is packaged, usually using appropriate packaging materials to protect it from damage during shipping and storage.
Classification of different LED lamp die casting designs
LED lighting has been developed for many years. LED lights for different purposes use different aluminum alloy materials, and the shapes and sizes of processing are also inconsistent. Mindwell has sorted out some classifications of aluminum die-casting for LED lights based on years of experience.
- Panel lights generally use aluminum profiles as the frame, plus aluminum corners, and aluminum back panels are assembled, such as 300mmX300mm. Panel lights also use aluminum alloy die-casting parts as frames. High-end panel lights generally use thick aluminum profiles plus oxidation, while ordinary ones use thin aluminum profiles plus spraying. There are also some circle-type, S-type, and runway-type Such as office and commercial panel lights are generally made of aluminum profile bending welding or riveting, and then hoisting after spraying;
- Floodlights generally use aluminum alloy die-casting parts to make aluminum shells. An aluminum radiator is installed behind the internal circuit board to increase heat dissipation. A bracket is added to the outside to facilitate fixed installation. The surface treatment of the die-casting shell is generally used for outdoor spraying. , some are sprayed with polyester, some are sprayed with fluorocarbon, and outdoor powders with special protection requirements generally use Fong’s, DuPont, Aksu, etc., in order to extend the service life of the outdoors, and the structural design requires strict dimensions of aluminum alloy die castings. The tolerance is small so that the glass can be installed and the waterproof level can be increased;
- Street lamps generally use large-scale high-multiple multi-tooth aluminum profiles as heat sinks inside. All of them are drilled and tapped to fix the circuit board. Lighting lights with high quality requirements are often designed as aluminum profiles + CNC milling cavity to bury the circuit board deeply. The way to increase the heat dissipation coefficient and heat dissipation effect; the exterior of the street lamp is generally made of aluminum alloy die-casting parts to make the protective shell, plus the sealing rubber ring to increase the waterproof level, and the surface is also carried out by outdoor powder spraying.
- Line lamps, landscape lamps, and wall washers are generally made of U-shaped aluminum profiles for fixed light strips or glue filling, and are generally used as outdoor lamps;
our company
Mindwell Aluminum Die Casting Company is a leading die casting manufacturer with many years of experience in providing high quality aluminum die casting solutions to various industries. Since our establishment in 2005, we have provided excellent products and services to customers all over the world with our professional technology and high-quality services.
Our company has rich experience in aluminum die-casting of LED lamps and has cooperated with many lamp manufacturers in this field. We are familiar with the manufacturing technology and process of lamp housings. Our professional team members are also proficient in the characteristics and processing of aluminum alloys, which can meet the needs of various LED lamp housings, whether it is to design unique shapes or require strict performance.
Our advantage
- High-Quality Manufacturing: Our aluminum die-casting process ensures consistent quality and precision for the LED light housings to the highest standards.
- Heat dissipation performance: We understand the characteristics of aluminum alloy materials, so our housing design has excellent heat dissipation performance, ensuring long life and high efficiency of LED.
- Customized Solutions: We are committed to providing customized aluminum die casting solutions to meet customers’ unique design and specification requirements.
- Sustainability: Our company cares about the environment and focuses on reducing waste and wasting resources. Insist on achieving zero pollution.
