Rapid Prototyping & On-Demand Manufacturing for
Lighting Industry
In an industry illuminated by energy-efficient innovation, we provide high-performance die-cast components that empower luminaire designs to shine brighter, last longer, and outperform expectations.
ISO 9001:2015 Certified
Instant pricing & DFM
Provides Finishing, Joining and Assembly
Design & Manufacturing Guidance from Industry Experts
CastMold Precision Lighting
Die Casting Solutions
CastMold specializes in premium aluminum die-cast components optimized for lighting industry applications. Our solutions are engineered to meet rigorous performance standards for both commercial and industrial lighting systems. Designed for LED housing, heat sinks, streetlight enclosures, and decorative fixture frames, our precision-cast components ensure reliable operation and extended service life in diverse lighting environments.
The die-casting process guarantees exceptional consistency and structural integrity, enabling seamless integration with optical modules, electrical circuits, and mounting systems. Our components deliver stable performance under continuous thermal cycling, vibration, and harsh weather conditions typical of outdoor and industrial lighting installations.
Thermal Management Excellence
High thermal conductivity rapidly dissipates LED heat, preventing lumen degradationLightweight Structural Durability
High strength-to-weight ratio enables slim, complex designs while resisting deformation.Corrosion & Weather Resistance
Anodized surfaces and IP65/68 enclosures withstand UV, moisture, and chemicals.EMI/RFI Shielding
Effective electromagnetic protection for smart lighting circuitry.
CastMold provide services from Prototyping to Production
Our Die Casting Capabilities
At CastMold, we specialize in high-precision die casting solutions tailored. Leveraging state-of-the-art cold-chamber and hot-chamber die casting technologies, we deliver high-volume production with exceptional dimensional accuracy and surface finish. Our expertise spans aluminum and zinc alloys, ensuring lightweight yet durable parts optimized for performance.
Equipped with automated systems and real-time quality monitoring, we achieve rapid cycle times while maintaining strict tolerances (±0.05mm). From prototyping to full-scale production, our end-to-end services include mold design, post-processing (CNC machining, plating, coating), and rigorous inspection (X-ray, CMM) to meet aerospace, telecom, and industrial standards.
Applications of
Precision Lighting Components
From custom-designed lighting housings to high-performance optical and thermal management systems, CastMold Lighting provides precision aluminum die-cast components that meet the demands of modern lighting solutions. As a specialized die-casting manufacturer, we offer the following tailored solutions:
LED heat sinks & housings
Outdoor fixture enclosures (IP66/IP68 rated)
Optical reflector assemblies
Architectural mounting brackets
Smart lighting sensor casings
Decorative luminaire frames
Weatherproof junction boxes
Specialist Industries
FAQs
Aluminum die-castings are ideal for lighting housings and heat dissipation components due to their lightweight, high thermal conductivity, and strong corrosion resistance. For example, LED fixtures demand superior heat dissipation, and aluminum’s high thermal conductivity (e.g., pure aluminum die-castings with a thermal conductivity of 192 W/m·K) significantly extends lamp lifespan. Additionally, its high-precision forming capability meets complex lighting design requirements.
- Lightweight: Reduces fixture weight for easier installation and transportation.
- Efficient heat dissipation: Enhances thermal management for LED fixtures.
- Corrosion resistance: Suitable for outdoor and harsh environments.
- Machinability: Enables intricate designs (e.g., textures and thin-walled structures) via molds.
- Cost-effectiveness: Mass production lowers per-unit costs.
Common Surface Treatments:
- Anodization: Enhances corrosion resistance and allows color customization.
- Powder Coating: Improves mechanical strength and weather resistance for outdoor fixtures.
- Sandblasting: Increases surface roughness for better adhesion.
- Eco-Friendly Chemical Polishing: Reduces pollution while improving surface finish.
- Porosity Defects: High-speed casting may cause internal voids, affecting anodization quality.
- High Mold Costs: Complex molds increase barriers for small-batch production.
- Process Compatibility: Traditional high-silicon aluminum alloys limit surface treatment options.
Sustainability Advantages:
- Recyclability: Aluminum has a recycling rate exceeding 90%, minimizing waste.
- Energy-Efficient Production: Mass production reduces energy consumption.
- Long Lifespan: Corrosion and thermal resistance extend fixture longevity, reducing replacement frequency.
Material Selection:
- ADC12: High fluidity, suitable for thin-walled components.
- YL112: Used for automotive and lighting structural parts; requires surface treatment to enhance corrosion resistance.
- Pure Aluminum: CastMold’s proprietary formula, offering high thermal conductivity and compatibility with anodization.
- High Precision and Miniaturization: Meets the demand for compact components in smart lighting.
- Green Processes: Nitrate-free polishing and low-energy surface treatments.
- Smart Production: AI-driven mold design and real-time process optimization.
Quality Control Measures:
- Mold Inspection: Regular maintenance to prevent burrs and dimensional errors.
- Non-Destructive Testing (NDT): X-ray or ultrasonic inspection to check internal porosity.
- Surface Testing: Salt spray tests to detect corrosion resistance; reflectivity checks to assess optical performance.
The heat dissipation of LEDs directly affects their luminous efficiency and lifespan. The high thermal conductivity of aluminum enables rapid heat dissipation, preventing luminous flux decay. For example, compared to traditional materials, pure aluminum heat sinks can reduce temperatures by over 20%.
