Die-Casting Lamp Mold for Aluminum Alloy Street Lights

• Custom cold-chamber die casting mold exclusively for aluminum alloy street light housings (pole-mounted, solar-integrated, high-power LED types), optimized for outdoor weather resistance and LED heat dissipation.

• Applicable to aluminum alloys (ADC12, A380) — ideal for street light parts requiring lightweight (3-8kg), high strength (tensile strength ≥220MPa), and anti-corrosion.

• Features 1-2 cavity configurations to match small-batch prototype (500 pieces) and high-volume municipal projects (100,000+ pieces).

• Achieves ±0.03mm dimensional accuracy (critical for street light lens/LED module assembly) and 500,000+ cycle lifespan for long-term production.

• Integrates mold-specific designs: 0.8mm-thin heat dissipation fins (for LED cooling), waterproof groove structures (IP65 rating support), and wind-resistant reinforcing ribs.

• Complies with industrial standards (ISO 9001, CE) and municipal project requirements (anti-UV, salt-spray resistance), supporting global B2B export.

  
  

• Heat Dissipation Optimization Cuts LED Failure by 40%: The mold’s cavity is engineered with 32 airflow-optimized fins (0.8mm thick, 15mm spacing) that increase housing heat dissipation area by 60% (vs. generic molds). This reduces LED operating temperature by 15℃ (from 65℃ to 50℃), extending bulb lifespan from 30,000 to 50,000 hours. A Thai municipal supplier installed 5,000 street lights using our mold—LED replacement costs dropped from \(12,000/year to \)7,200. The mold’s internal cooling channels (0.6mm wall thickness) also shorten casting cycle time by 18% (from 45s to 37s), supporting high-volume municipal projects.

• Outdoor Anti-Corrosion Design Extends Housing Life to 10 Years: The mold’s cavity surface is coated with a nanoscale ceramic-fluorine composite (12μm thick) that creates a barrier against salt spray, UV rays, and humidity. This gives street light housings a 1,000-hour salt-spray resistance rating (ASTM B117), vs. 500 hours for uncoated molds. A coastal city in Malaysia reported just 5% housing corrosion after 3 years (vs. 30% with generic molds), avoiding $30,000 in warranty replacements. The H13 die steel (52-54 HRC hardness) also resists mold wear from aluminum oxide, ensuring consistent fin detail for 500,000 cycles.

• Precision Ensures Seamless Assembly with LED Modules: Achieves ±0.03mm dimensional accuracy via CNC grinding (tolerance ±0.005mm) and EDM wire cutting (surface roughness Ra 0.2μm). This ensures street light housings align perfectly with LED modules and waterproof gaskets—no gaps that cause water ingress. A Chinese lighting supplier producing 10,000 housings/month reduced assembly failure (water leaks, misalignment) from 8% to 1%, saving $16,000/year in rework. The mold’s built-in alignment marks (etched into cavity) eliminate manual measuring during lens installation, cutting assembly time by 30% (from 10 to 7 minutes per unit).

• Structural Strength Resists Wind and Impact: The mold’s cavity includes 4 reinforcing ribs (3mm thick) at key stress points (top mounting, bottom base) — increasing housing bending strength by 45% (from 180MPa to 261MPa). This lets housings withstand 120km/h winds (common in tropical storms) without cracking. A Philippine municipal project tested 1,000 housings in a typhoon zone—zero structural failures, vs. 15% with generic molds. The mold’s 2-cavity configuration also supports high-volume production (2,000 housings/day), ideal for citywide lighting upgrades.

• Low Maintenance Reduces Production Downtime: The mold’s cavity surface coating is scratch-resistant (1H pencil hardness) — no damage from aluminum scrap during casting. This reduces cavity cleaning time by 70% (from 30 to 9 minutes per shift). The mold’s guide pins use self-lubricating bushings (PTFE-lined) that require no monthly oiling—saving maintenance teams 4 hours/week. A U.S. lighting manufacturer with 5 molds reported spending just 2 hours/month on maintenance, vs. 8 hours with generic molds.

• Urban Municipal Street Lights (Pole-Mounted, 100-200W): Ideal for 300T-400T die-casting machines—producing 5kg ADC12 housings with 32 heat dissipation fins. A Chinese city used 2,000 housings from our mold for downtown lighting—LED replacement costs dropped by 40% in the first year, and the city renewed the supplier’s contract for 5 years.

• Solar-Integrated Street Lights (Rural Areas, 50-100W): Perfect for 2-cavity molds—producing lightweight 3kg housings (to reduce pole load) with integrated solar panel mounting brackets. A Kenyan rural lighting project ordered 1,500 solar street lights— the mold’s precision ensured solar panels aligned with charge controllers, reducing installation errors from 10% to 1%.

• Highway/Industrial Street Lights (High-Power, 200-400W): Suitable for 500T-600T machines—casting 8kg high-strength A380 housings with 4mm-thick reinforcing ribs. A European highway authority tested 800 housings in a 120km/h wind tunnel—zero structural failures, leading to a $2M annual order.

• Coastal/Marine Street Lights (Salt-Spray Environments): The mold’s anti-corrosion coating makes it ideal for coastal cities—housings resist salt spray for 1,000 hours. A Singapore coastal park installed 300 street lights—after 2 years, just 2% showed minor corrosion (vs. 25% with previous suppliers), avoiding $12,000 in replacements.

Street Light Design Consultation (3-4 Days):

• Our engineers review your street light 3D models (STEP/IGES) and project requirements (power: 50-400W, environment: urban/coastal, lifespan: 5-10 years).

• We recommend optimizations: e.g., adding 2 extra reinforcing ribs for highway lights, thickening the coating for coastal projects.

• Example: For a 200W highway light, we adjusted fin spacing from 15mm to 12mm to improve heat dissipation—reducing LED temperature by 8℃.

Cavity Design & Simulation (7-9 Days):

• Create 3D mold models with specialized features: waterproof grooves (for IP65), fin patterns, and mounting brackets.

• Run flow simulation to test aluminum filling (avoids air bubbles in fins) and thermal simulation to ensure even cooling (prevents fin warping).

• Share designs with your team for feedback—95% of customers approve after 1-2 iterations.

Mold Material Selection & Preprocessing (5-6 Days):

• Source H13 steel from certified mills (with MTRs) and cut to mold blank size via CNC sawing.

• Apply initial heat treatment (annealing) to reduce steel stress—critical for preventing mold warping during casting.

• For coastal projects, pre-treat the cavity with a primer layer (improves coating adhesion).

Precision Manufacturing & Coating (10-12 Days):

• Use CNC milling (tolerance ±0.005mm) and EDM wire cutting to shape cavities, fins, and cooling channels.

• Polish cavity surfaces to Ra 0.2μm and apply nanoscale anti-corrosion coating (cured at 200℃ for 2 hours).

• Assemble mold components (guide pins, cooling fittings) and test mechanical movement (mold opening/closing) to ensure smooth operation.

Test Run & Delivery (3-4 Days):

• Conduct a test run on our 400T die-casting machine (using ADC12 aluminum) to produce 100 sample housings.

• Inspect samples via CMM (dimensional accuracy) and salt-spray testing (for coastal projects)—share reports with your quality team.

• Deliver the mold with a kit (spare guide pins, coating touch-up tool) and provide on-site installation guidance (free for orders over 1 mold).

• Material Quality Checks:

• H13 steel is inspected via ultrasonic testing (UT) to detect internal cracks—rejecting any blanks with defects.

• Anti-corrosion coating thickness is measured with a profilometer (12±1μm) and adhesion is tested via cross-cut method (ISO 2409, 0 级).

• Dimensional Precision Testing:

• Use a Zeiss CMM (accuracy ±0.001mm) to measure fin thickness, waterproof groove depth, and mounting hole position—all data logged in a traceable report.

• For every 100th sample housing, conduct a torque test (mounting brackets must withstand 50N·m without deformation).

• Compliance for Municipal Projects:

• Full compliance with ISO 9001 (quality management) and CE (EN 10204 for material traceability).

• For global projects: meet ASTM B117 (salt-spray), ISO 10289 (aluminum die-casting), and IEC 60598 (lighting safety) standards.

• Post-Delivery Validation:

• We provide 1 week of on-site support after handover—adjusting mold parameters to ensure your die-casting machine produces 99%+ 合格 housings.

• For large municipal orders (10,000+ housings), we assign a dedicated engineer to monitor quality for the first month.

• Pre-Operation Checks (4 Minutes/Day):

1. Inspect cavity surface: Check for scratches or coating wear—use a touch-up pen (provided) to repair minor damage (avoids housing defects).

1. Test cooling water flow: Ensure 80L/h flow rate (low flow causes fin warping)—clean filters if pressure drops below 0.3MPa.

1. Verify guide pin alignment: Run a dry mold opening/closing cycle—listen for abnormal noise (sign of misalignment, adjust immediately).

1. Check aluminum quality: Use only ADC12/A380 with ≤0.5% iron content (high iron causes surface defects on housings).

• Weekly Maintenance (1.5 Hours):

1. Clean cooling channels: Flush with a biodegradable cleaner to remove scale buildup—improves heat transfer and reduces cycle time.

1. Lubricate guide pins: Apply high-temperature grease (provided) to pins—avoids wear and ensures smooth mold movement.

1. Inspect coating integrity: Wipe the cavity with a lint-free cloth—if the surface feels rough, the coating needs reapplication (contact our team).

• Monthly Maintenance (2.5 Hours):

1. Calibrate mold clamping force: Use load cells to adjust to 400T (for 2-cavity molds)—over-clamping causes cavity deformation.

1. Inspect cooling fittings: Tighten loose connections (vibration loosens them) and replace O-rings if leaking—prevents water damage to the mold.

1. Conduct a sample test: Cast 10 housings and inspect fin thickness (0.8±0.05mm) and surface finish—adjust parameters if deviations exceed limits.

• Warranty Coverage:

• 2-year warranty for the mold body (covers cracks from normal use) and 1.5-year warranty for the anti-corrosion coating (covers premature wear).

• For coastal projects, extend coating warranty to 2 years (50% extra cost)—a Singapore supplier used this to meet the city’s 5-year housing warranty requirement.

• 24/7 Technical Support:

• Our team of 3 lighting mold engineers (10+ years experience) offers round-the-clock help via phone, WhatsApp, and video call.

• For urgent municipal projects (e.g., hurricane recovery lighting), we respond within 20 minutes and provide expedited spare parts.

• Spare Parts & Coating Kits:

• Stock anti-corrosion coating kits, guide pins, and cooling O-rings in 3 regional warehouses (China, Germany, U.S.).

• 24-hour delivery to major industrial hubs— a U.S. supplier received a coating kit in 12 hours, minimizing downtime to 1 day.

• On-Site Training:

• Free 2-day training for your operators and maintenance team—covers mold setup, parameter adjustment, and coating touch-up.

• A Kenyan supplier’s team reduced mold-related defects from 7% to 1% after training, mastering skills like “optimizing cooling for solar light housings.”

• Specialization in Street Light Mold Design: We don’t make generic aluminum molds—we focus exclusively on outdoor lighting, with 15+ years of experience in street light heat dissipation and anti-corrosion. Our R&D team tests every mold in real outdoor conditions (salt-spray chambers, UV labs) to solve actual municipal pain points.

• Proven Track Record with Municipal Projects: Over 150 lighting suppliers in 40 countries use our molds, including suppliers to cities like Singapore, Bangkok, and Los Angeles. A Chinese supplier completed a $5M municipal lighting project using our molds—delivered 100,000 housings on time with 99.8% pass rate, winning a 3-year contract extension.

• Transparent ROI for Municipal Contracts: We provide a customized ROI calculator (based on your housing production volume, LED replacement costs, and warranty claims). Most customers recoup investment in 12-16 months—for a supplier producing 50,000 housings/year, this means $80,000 in 5-year savings (corrosion replacements + LED failures).

• Municipal Compliance Expertise: We assist with project certifications (e.g., ASTM, IEC) and provide detailed documentation (material MTRs, test reports) for municipal audits. A European supplier used our documentation to win a highway lighting contract, as we met the EU’s strict environmental standards.

• Flexible Lead Times for Urgent Projects: Standard molds (1-2 cavity) are in stock (delivery 7-10 days). Customized molds take 25-30 days—40% faster than competitors (40+ days). A Philippine supplier received 2 custom coastal molds in 28 days, meeting a typhoon recovery project deadline.

• Q1: Will this mold work with our existing 400T Yizumi die-casting machine and produce our 6kg solar street light housing?

• Q2: How long does the anti-corrosion coating last on the mold, and can we reapply it ourselves?

• Q3: Can the mold produce street light housings with different fin counts (we need 24 fins for 100W lights and 36 for 200W)?

• Q4: Does the mold support production of housings with IP65 waterproof ratings, and how do we verify this?