Luminaire design

workflow


EVALUATION OF THE PROJECT

Customisation starts with a clear understanding of the problem you are trying to solve. Maybe it’s a specific shape, colour or optical configuration you need - if so, we can help.

If you need a complete system integration, custom programmable drivers or materials, we can help.

Our skilled and experienced team are on hand to help you with whatever you need to make your lighting project a success. 


DESIGN AND ENGINEERING

• Industrial design - This is the process of preparing 3D designs using 3D CAD modelling software. The process allows us to implement any adjustments you wish to make immediately.

• Optical Design - We prepare optical designs according to the requested illumination, beam angle, UGR and efficiency and efficacy specifications. The optical designers also take into account the materials asked for or can offer new technologies based on our internal research.

• Thermal Design - The thermal design process starts with the simulation and suggestion of appropriate heatsinks made of optimised materials that ensure the smallest possible luminaire. We focus on self-designed and highly effective heatsinks that boast excellent thermal conductivity properties despite their compact size.

• Electronic Design - The electronic department prepares electronic designs for PCBs as well as suggesting the most suitable components and electrical schemes. They can also propose the software and interface needed for touch panels, computers and other devices in order to make control of the luminaire as easy and flexible as possible.

• Mechanical Design - Our mechanical designers and engineers prepare sheet metal, die cast and extrusions designs according to the type of luminaire, using the advanced Adobe Fusion 360 software. The designers ensure that the desired mechanical properties are provided, especially in the case of requested IP and IK protection ratings.


Prototyping

Nowadays, speed is a key factor in the successful development of a product. Faster is better and ultimately saves money. 

With our own industrial 3D printer, we can produce prototypes in a suitable timeframe for your project . Additionally, our mechanical workshop is equipped with a wide range of traditional machines that allow for turning, milling, cutting, bending and welding so we can provide fully functional prototypes and samples within just a few working days.

We can also manufacture prototype PCBs and equip prototype luminaires with these PCBs in order to perform all necessary luminous flux, thermal and EMC measurements.

Prototypes enable us to check the functionality of parts before any expensive tooling investment is made. Design flaws and other issues can, at this stage, be resolved.


Tooling

Tooling involves the development and production of die-casts, extrusion tools, or injection moulds. Through the years of experiences with manufacturing and design, we have built an extensive network of proven and trustworthy tooling suppliers that can provide a wide variety of tools.

• CNC Machining - is a process used in the manufacturing sector that involves the use of computers to control machine tools. There are many advantages to using CNC Machining. The process is more precise than manual machining, and can be repeated in exactly the same manner over and over again. Because of the precision possible with CNC Machining, this process can produce complex shapes that would be almost impossible to achieve with manual machining. CNC Machining is used in the production of many complex three-dimensional shapes. It is because of these qualities that CNC Machining is used in jobs that need a high level of precision or very repetitive tasks.

• Extrusion - Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections, and to work materials that are brittle, because the material only encounters compressive and shear stresses.

• Aluminium Forging - Forging requires the use of materials that are able to withstand extreme processes such as heat, pressure and mechanical stress, but the results are suitable for mass production and deliver some outstanding material properties. For example, the thermal conductivity of a forged heatsink is double that of an extruded one, resulting in a much smaller and lighter weight product.


TESTING AND EVALUATION

At Ledtroniks, we have some of the best equipped inhouse laboratories in UK, and can provide our customers with extensive and indepth services thanks to the array of tests we can perform side-by-side with our other services. This provides development flexibility and speed not possible if these tests needed to be outsourced.

Another advantage is that tests can be performed on final prototypes before they go to the next stage, tests that would normally be very time consuming. 

After finalisation and testing of the prototype, if certification by a third party is required, the product is sent to the appropriate certification laboratory. As we perform all tests in-house beforehand, the possibility that the product fails any official laboratory test is eliminated. This ensures that the final release of your product to the market is not unnecessarily delayed.


PRODUCT COMPLETION

• Release From Development - Once we have the test reports and certificates issued by the certification laboratories, the next step is to release the product from R&D. During the release meeting, the final prototype, as well as test reports and samples, are compared to the product definition form. If the result is satisfactory, the product is released from development following a defined release protocol that needs to be signed by all responsible parties.

When the product is officially released from development, you are also supplied with full technical documentation.

CONTACT US TODAY!

AND LET US KNOW YOUR SPECIFICATIONS

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