Whether your business offers many LED lights to high-rise buildings or streetlights to small towns, it will be difficult to find the right die caster for your business. Components of LED lights are made with aluminum pressure die casting as it offer great dimensional accuracy, besides being durable and sturdy.
In case of the LED lights, thermal design is very important to ensure the lifespan of both the light and the fixture. More and more LED light fixture designs are now available that use aluminum die casting. However, the low unit price and the flexibility in graphic design are the major reasons to make use of aluminum die casting to manufacture LED light fixtures.
Aluminum Die Casting for LED Lighting Industry
Die casting is a very efficient way to work with copper, zinc, and aluminum alloys. As said, the process can ensure dimensional accuracy, and so, little to no machining is needed to finish the products. In fact, die casting is the best way to mass produce ornate LED light fixtures economically. The properties of aluminum make it a suitable metal for die casting and moreover the metal is lightweight and non-toxic.
Some of the different methods of die casting that are used to make aluminum LED light fixtures are:
Gravity Casting or Permanent Mold Casting
The process of gravity die casting or permanent mold casting is very similar to aluminum die casting, except for a few changes that make is east to work with light metals. The process employs reusable molds made from metal and use gravity to fill the mold. However, in some of the cases, the die caster may use vacuum or gas pressure.
Liquid Forging
Liquid forging is a hybrid of casting and forging process and can be a good option in cases where high integrity is necessary. For instance, the manufacture of heat sinks for LED lights. In this process, a fixed quantity of molten metal is poured into the cavity and is squeezed under pressure while the metal solidifies in the cavity. The advantage of this process is that the components can be made in a single process.
An added advantage of using aluminum to make LED light fixtures is that as the metal is non-corrosive, it is the perfect choice for outdoor use. For outside lights and streetlights, die cast aluminum that imitates cast iron is much sought after.