Hi everyone,


For a small group of investors my business partner and I created a design for a lamp. Our design is very basic and consists of some plastic parts, some aluminium parts(like a control button, a dimmer switch and a lampshade) and a bit of wiring. We especially like the combination of high quality plastic and brushed (or maybe anodised) aluminium.

Our investor has approved our design and commissioned us to compose a list of manufacturers who can advise and accompany us in the process of prototyping, refining and ultimately manufacturing of our product. We have done some research and came across this amazing forum and decided to ask for some help, so here we go;

1A)
Is it customary that manufacturers are capable to manufacture both plastic and aluminium parts in house? Or is it more common that, for example, the aluminium moulding is outsourced?
The reason behind this question is that our research has shown that both techniques are (very) similar.

1B)
And in both cases, is it customary that the finished parts are assembled in the primary factory?
Does this imply that the electronic parts and wiring will also be assembled in the primary factory?

2)
Our research has also shown there a many techniques of manufacturing and moulding for both materials. Could you advise or recommend one or multiple techniques to create high quality, light and strong plastic or synthetic parts? Could you advise or recommend one or multiple techniques to create brushed or anodised aluminium parts?

Our preferred region of production is Singapore (with possibly a plant in China).


Thank you all in advance.

Regards,
Fred.

 

Hi Fred,

I am a design & manufacturing consultant with connections to many Asian suppliers, and I can definitely help you out here, but I would need some more information to be able to give helpful answers.

Please contact me at [email protected] for more information.

Regards,
Jeff

 

Hi Jeff,

Thank you for your reply.

What kind of information do you need?
And what kind of support can you provide?

Regards,
Fred.

 

reply

Hi Fred,

There are many large manufacturers capable of manufacturing and assembling in-house, and there are many more capable to do the assembly level and then sub-contract the part manufacturing to a network of specialists.
The choice of supplier often comes down to the required manufacturing processes, volume and value of business, cost vs quality requirements, and relevant product experience.

The choice of manufacturing processes depends heavily on the product geometry, choice of materials and volume of production.

I would therefore need some more information on the product geometry, product specifications (cost vs quality vs performance priorites) and the intended production volumes.

What I can offer is product industrialisation / design for manufacture, introductions to appropriate Asian suppliers, supplier management, production readiness assessment, and product quality alignment. See www.jefmek.com for further information.

Initial advice is always free and without commitment, so please contact me via email at [email protected]

BR
Jeff

 

Hi Fred,
I`m mechanical engineer in production of LED floodlights, and warehouse LED light.
Here is my experience about your problem that You mentioned:
1A) Moulding plastics and aluminium is similar process but not the same. I think that company`s who are doing both, are not perfectly good in anything. For me, better is to find company for moulding plastic and especially company for moulding aluminium.
1B) For me ,from my so far experience, the best you can do is to assembly complete product in primary factory. All components electrical or mechanical came on same place and then do the assembling. That way you can momentarily react on problem which may happen during assembling, and your product is safest that way before you start selling.
2) You can do a plastic housing, very nice and good quality, for little money. Brushed aluminium is not the same as anodized aluminium. You can produce aluminium parts by molding and then brush them. If we talk about anodization, you can not anodize moulded aluminium in good quality. You must produce parts from extruded base by mechanical processing, and then you can anodize in good quality.
I produce all of my product in Serbia. One company produce lenses for me (plastic), second rubber, third aluminium extruded profiles, and all of the parts they produce, I assembly in my company. I think that is the best way.
Best regards,
Djordje

 

Hi Fred,

plastic mould machines and aluminum mold machines are very different both in size and in method of operation. most of the manufacturers specialize in the former or the latter and i don't recall hearing of a plant mixing both technologies so there will have to be some more logistic effort on your side if you want to use both technologies in your product. regarding assembly lines there are plastic mould factories that can make simple assemblies but it you're into the led buisness where build quality is very important i suggest you use a third party to have the job done. i'm sorry to disapoint you but there are no shortcuts here - each operation will have to be done by a different contractor and you job will be to coordinate and oversee that the various steps are done correctly and with good quality. as for special plastics and materials you should hire a plastics engineer to advise you on that. good luck with your project!

 

Hi Fred,

I have some proposals about your questions:

1A)If possible, it is better to have the plastic and aluminum parts in the same company. It is easier to control the cost and quality.
Of course, if it is difficult to find such company, look for a company can well deal with the plastic project in house and also can have good source to outsource the aluminum parts.

2B)Since the composition of the lamp is not complicated, it is better to have the electronic parts and wiring assembled in the primary factory.

2)As per my experience, the plastic parts should be made from plastic injection molding, and aluminum parts should be made from die casting or stamping. It depends on the specific structures and material for the aluminum part.

We are a mold company in China, manufacturing plastic injection molding products and die casting products. We make some parts of LED lights for Philips. The parts are made of aluminum ADC12, from die casting.

You can send your product drawings/other information to me, i can have our engineer review and make some proposals for the manufacturing method.

Best regards,
Lyn

 

Hi,Jeff, is it difficult to find one company who has this two kinds of manufacturing, plastic injection molding and aluminum high pressure die casting, to control the quality well enough, you can choose one best company and give them all your components, of course, they have to subcontract some parts but they have to control the quality themself,if you find different suppliers and cooperate separately with individual, it works if you have strong and strict quality system and QC staff