Die Cast Lighting Fixtures & LED Housings

Lighting fixtures are a thermal product disguised as a housing. An LED fixture that runs 10°C cooler keeps roughly double the LED lifetime - which is why die cast aluminum with integrated heat sink fins dominates professional flood, street, and high-bay lighting. KastMfg casts lighting housings from compact downlight bodies to 1,600T-class stadium flood light frames.

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The Lighting Product Range

• Flood light housings - 30W to 1000W-class bodies with cast fin fields and glare shield features
• Street light enclosures - cobra-head and post-top bodies with IP65-IP67 sealing
• High-bay and low-bay fixtures - UFO-style round housings with radial fins
• Downlight and track light bodies - compact Zamak and aluminum housings
• Explosion-proof and industrial fixtures - heavy-wall housings for hazardous locations
• Bollard and landscape lighting - corrosion-protected outdoor bodies

For the industry-level view, see LED lighting die casting; for thermal management in electronics generally, see our heat sink housings.

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Design Features That Matter in Lighting Castings

Integrated fin fields

Fins cast directly into the housing eliminate the thermal interface of bolted-on heat sinks. Practical cast fin geometry: 1.5 to 2.5 mm fin thickness at the base, 2 to 3 mm spacing, draft of 1.5 degrees minimum - deep, dense fins are where A383's superior die-filling earns its premium over A380.

Sealing for outdoor ratings

IP65-IP67 ratings are won or lost at the gasket groove. We cast and machine O-ring grooves to ±0.1 mm width tolerance with flatness verification on sealing faces - the same discipline as our electronics enclosures.

Driver compartments and cable management

Cast-in driver cavities, cable gland threads (M20/M25 or NPT), and strain-relief features eliminate secondary fabrication. Stainless clips and stainless hardware compatibility are reviewed at DFM to prevent galvanic pairing issues.

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Alloys and Finishes for Lighting

Choice	When
ADC12 / A380	Default for most fixture bodies
A383	Dense fin fields and very thin walls
Powder coat (outdoor-grade polyester)	Standard finish, RAL colors, UV-stable
Anodizing	Not recommended on high-silicon die casting alloys - powder coat instead

Outdoor fixtures get 500 to 1,000 hour salt-spray-qualified powder systems as standard, with coastal-grade options for marine environments.

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Program Notes for Lighting Buyers

• Thermal validation: we support thermal simulation review at DFM so fin geometry is right before tooling
• Photometric mechanicals: mounting boss positions and aiming features cast to drawing, machined where aiming tolerance demands it
• Volume flexibility: lighting programs often start at 1,000 to 5,000 pieces for market testing - see low-volume die casting
• Certification support: material certificates and RoHS documentation for UL/CE listing files

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Related Products

• die cast electronics enclosures - IP67 and EMI housings
• heat sink housings - thermal-first housings
• die cast products - full product families
• aluminum die casting - alloy and process capability

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Lighting fixture inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China