kineticdiecasting.com

The main purpose of lighting fixtures or parts is to create artificial light. A lighting fixture consist of 0 parts—the light source, light reflector that directs the light to a certain point, an opening (with lens or without lenses), the light housing for protection, an electrical counterweight, and a cord connecting to the power source. Lighting fixtures can be classified as indoor lighting fixtures and outdoor lighting fixtures.

Before the introduction to an aluminum die casting company, lighting parts are made by welding pieces together. This process is costly, time consuming, and labor extensive. Nowadays, lighting parts are manufactured by die casting, a process wherein molten metal is forced into mold cavities. Die casting is beneficial if you are producing large quantities of small to medium sized lighting parts with good details,

Aluminum is lightweight and sturdy, a material often used to make lighting parts because of its durability and good thermal and electrical properties. Die cast aluminum lighting parts are made faster because they can be produced in net shape, meaning there are no welding or drilling methods needed after. Holes can be added to the mold cavities. These holes are necessary for the installation of covers or lids.

Die cast aluminum lighting parts are used in medical offices and parking garages for lighting fixtures. They are also used for bullet lighting fixtures, street traffic lights, outdoor and wall lighting fixtures. Furthermore, there are special light parts made for Aluminum lighting fixtures used for automobile lighting, marine lighting, medical lighting, and aerospace lighting.

Another California Die Casting Company closed their doors in 2007, Cascade Die Casting/ Pacific (aka CDC).

This is the information Cascade Die Casting/ Pacific published as their capabilities and mission:

Cascade Die Casting/ Pacific
950 Turnbull Canyon Road
City of Industry, California 91745

Mission for Cascade Die Casting/ Pacific:
We are a leader in the manufacturing of high quality, high value aluminum and zinc cast products and services for our customers. We will accomplish this mission through:
- employee involvement and commitment
- continuous improvement of our people and processes
- ongoing advancement of design and engineering capabilities
- utilization of our national presence

Materials:
Die Cast Aluminum Alloys: A380, A383, zinc and specialty alloys upon request

Capabilities:
Die Casting
High Pressure Die Casting Machines: 400 to 1200 ton
Fully automated die cast cells, shot and process monitoring

Secondary Finishing
Full service finishing including sanding and vibratory deburring
CNC and dedicated machining, testing and sub-assembly

Facilities
Plant 1: 80,000 sq. ft. manufacturing and office space

Customer Service
Production control & material handling JIT/EDI services
Coating processes with certified sub-suppliers
chem-film, anodize, plating and powder paint

Engineering Services
Product, tooling & process engineering, project management
Solid Works, AutoCAD Mechanical Desk Top
Solid Modeling, flow simulation rapid and die cast prototyping capabilities

Major Products:
safety restraint components
seating frames, components
electronic heat sinks, housings
compressor/pump components
power tool tables, brackets, covers
speaker and telephone housings, frames

Key Markets:
Automotive
Telecommunications
Consumer Electronics
Power Tools
Office Furniture
Other

Cascade Die Casting/ Pacific is another example of how difficult it is for a die casting manufacturing company to stay in business in California. Cascade had a long history of being a great supplier here in California and Cascade Die Casting/ Pacific will be missed by their former employees, their suppliers and their customers who need aluminum die casting parts.

Kinetic Die Casting continues to be strong while other die casting companies are closing down or selling out.

Aluminum Die Casting Lighting Fixture Parts from aluminum sand castings. A customer who is a lighting parts manufacturer purchases an aluminum sand casting fixture for his lighting products. This sand casting is an “Aluminum Trolley Mount” used to hold his lighting fixtures from the ceiling in a room. This aluminum trolley fixture has to be strong and look good to be part of his lighting products. He has been using this aluminum sand casting for quite a long time. The initial sand casting cost less to get started with a new product line and die casting cost a little more. The sand casting tooling costs less than $5000 to get started and the part price in this case is about $70 each part. My customer buys about 50 parts a month. His total cost to purchase these castings in a year after the tooling is paid for would be $70 per part times 12 times per year times 50 parts per month ($42,000 per year). Can this part be cost effectively produced as an aluminum die casting lighting fixture?

Aluminum Lighting Fixture Die Castings
The die casting part will require die cast tooling. This tooling will take about 10 weeks to be made and will cost about $28,000 to be made. This seems too expensive for some but if the annual total cost is calculated it will show that the tooling cost is justified. The part price in this case is $8 each part. A simple calculation will show the cost of the die castings with the die casting tooling will be better than the cheaper sand casting price.

Aluminum Die Castings
Part Price — $ 8.00
Annual Quantity — 600
Total parts cost — $4,800
Tooling cost — $28,000
Total product cost — $32,800

Aluminum Sand Castings
Part Price — $ 70.00
Annual Quantity — 600
Total parts cost — $42,000
Tooling cost — Paid for already
Total product cost — $42,000

The aluminum die casting option will cost about $9,000 less the first year and over $30,000 less each year afterwards. Die casting aluminum is a better option.

Many lighting fixtures are made with aluminum diecasting. Fixtures for Lighting is a fashion business and Aluminum Lighting Fixtures are always at the forefront of the industry. Be it new styles, new products or new technology, Fixture Lighting is leading the way. Look to us for Design Inspirations and a sneak peek at what the best in lighting has to offer.