LED lighting technology as a challenge for die-casters.

Another example of the complexity of die-casting technology is the LED headlight for the automotive industry.  Besides the actual support function for the LED  the main tasks of the main castings are to accommodate the heat and the specific lead of it which, due to its special characteristics, makes aluminium a most suitable material. Narrow position tolerances for the carrier of the LEDs and a high degree of precision needs to be implemented.
Only then is the result a light cone without a scattering of individual LEDs. 


Heat reduction bracket for LED headlamps.


Request & challenge:   Flatness 0.2 for the whole casting, casting dimensional accuracy of all geometries without mechanical finishing, max. thermal conductivity, local flatness of 0.5, riveting possible, fatigue strength, pre- assembly, traceability and identification of every item and matrix printing.
Weight:   0.6 kg
Alloy:   230 D


Heat reduction bracket for LED daytime headlights


Request & challenge:   robust, high thermal conductivity, low porosity despite wall thicknesses of 1.5 – 12 mm, LED conductor pad flatness 0.05 without mechanical machining, gasket ready cast without post  processing, positioning accuracy of the underfloor slider
Weight:   0.2 kg
Alloy:   230 D


Heat reduction bracket for LED rear lights


Request & challenge:   Flatness 0.05 of conductor surface, maximum heat dissipation via fine fins, maximum standard of cleanliness and absence of particles, all geometries ready cast
Weight:   0.3 kg
Alloy:   230 D