Die Cast Aluminum LED Housing Case Study
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About the Project
This project involved the custom production of a die cast aluminum LED housing for outdoor lighting applications. The design required precise dimensions, efficient heat dissipation, and high surface quality. ZH Precision completed the project using a full workflow including die casting, post-processing, and CNC machining, ensuring the product met strict functional and aesthetic requirements.
| Industry | Electronics / Outdoor Lighting |
|---|---|
| Product | Die Cast Aluminum LED Housing |
| Services Provided | Custom Die Casting, CNC Machining, Post-Processing |
| Technology | Aluminum Die Casting, CNC Machining, Powder Coating |
| Materials | ADC12 Aluminum, Copper (for heat pipe) |
| Surface Treatments | Chemical conversion coating, Powder coating, Polishing |
| Key Features | Precise dimensions, Multi-feature design, Embedded heat pipes, High surface quality |
| Quality Control | IPQC, FQC, OQC inspections, Go/no-go gauge checks, Visual & dimensional inspections |
Project Challenges
1.Complex structure with multiple features and bosses requiring accurate die casting and subsequent CNC machining.
2.High heat dissipation requirements, ensuring copper heat pipes were embedded without deformation or air bubbles.
3.High surface quality standards, with zero defects such as material shortage, burrs, or scratches.
4.Multiple IPQC (In-Process Quality Control) and FQC (Final Quality Control) checks were required to ensure consistency across the production batch.
Production Solution Overview
For this die cast aluminum LED housing project, ZH Precision provided a complete end-to-end manufacturing solution to meet the client’s high-precision and performance requirements. The solution included:
Custom Die Casting
Precise aluminum casting using ADC12 material to achieve complex geometries and multi-feature designs.
CNC Machining
Critical areas, including inlets, outlets, and mounting points, were machined to exact tolerances to ensure fit and function.
Embedded Heat Pipe Integration
Copper heat pipes were accurately positioned to guarantee efficient thermal management without deformation or air bubbles.
Surface Treatment
Chemical conversion coating, powder coating, and polishing were applied to meet strict appearance and durability standards.
Quality Assurance
Multi-stage IPQC, FQC, and OQC inspections ensured consistent dimensions, surface quality, and functional performance across the entire batch.
Packaging & Shipment
Products were carefully packed with protective materials to prevent damage during transportation and shipped with full documentation and inspection reports.