Reflector assembly, their design and manufacture
You’ve guessed it, today I’m talking about the latest batch of reflectors we recently made in our factory! So if you’re interested in the process of reflector assembly then please read on.
Reflector slots and tabs
Using the method of 3D modelling we were able to accurately calculate the reflector shapes and sizes that would fit together to produce the final reflector assembly. Each part is made using the same material, Alanod 33PG 0.4mm thick reflector aluminium. The 4 individual pieces of metal are joined together to produce a circular reflector.
The red sections have tabs on their outer edges, these fit in to corresponding slots on the sides of the green sections. Tabs and slots allow for a cheap method of assembly as other components such as bushes and studs are not required. In addition, the method of assembly is relatively easy. The reflectors could be assembled by V and F Sheet Metal or the customer, the choice is there. It goes without saying that this method of assembly is only useful when the metal being used is thin and soft enough to be deformed by hand.
After the modelling using Radan software we need to develop the flat blank and nest the components together to produce the best yield from the material. In this case both parts have been mixed together in the same nest. Parts were punched out on our Trumpf 200 CNC punch press from sheet aluminium 2m long x 1.25m wide.
As you can see in the final image, the material used has a convex hammer pattern, but it is also available in a concave design. The convex arrangement produces a soft lighting effect which would be useful in certain situations where a soft/background lighting is required.
Punched reflector component
And the next step is
If you have a product that you think may benefit from using tabs and slots then please give us a call on 01489 577786 or email if you prefer at email@example.com. Our sheet metal engineering team are always happy to help and love a challenge. With over 50 years experience between them there’s not much they haven’t come across in the world of lighting.
For a range of lighting and past reflector projects take a look at our Pinterest Lighting Board.