The client is an established UK based manufacturer of high quality LED lighting for communal spaces, hotels, airports and new housing developments. They approached Hillside Product Design looking to add a new luminaire to their range which could incorporate their existing electronic assemblies. Due to the wide range of possible applications, the new luminaire is required to meet IPX5 for water ingress.
The client specified that the component should seal with as few fasteners as possible. An existing diffuser component was chosen from the client’s range to be modified, to save the expense of commissioning a new mould tool. Hillside Product Design carried out leak tests to optimise the seal around the diffuser, identifying that a gasket face which matched the catenary between the fastening points would create the best seal possible.
Using prototypes CNC machined from billet polycarbonate, the design was reviewed and modifications were made to accommodate both existing and future electronics and lighting arrangements. 2D specification drawings and 3D CAD files were prepared by Hillside Product Design, and the tooling was commissioned.