Metal stamping is a cold-forming technique wherein a flat sheet or coiled metal material is pressed into a tool and die surface with a stamping press to form it into the desired configuration. Due to its versatility and precision, metal stamping plays a significant role in the manufacturing of lighting components for commercial, residential, and industrial applications. It enables the production of uniquely-shaped metal lighting fixtures and hardware with tight tolerances and unparalleled levels of accuracy. Furthermore, the superior design flexibility achieved through metal stamping makes it well-suited for fabricating lighting solutions that are both visually appealing and practical.
Advantages of Using Metal Stamping in Your Lighting
Metal stamping offers a number of unique benefits that make it a favored production method for a large variety of applications. In industrial and commercial lighting applications, the stamping process offers the manufacturing flexibility required to accommodate the widely varying geometries and intricate features that are often associated with lighting housings, brackets, and other components.
A few of the most notable advantages of this metal forming process include:
- Cost efficiency. Metal stamping can accommodate both high- and low-volume orders in a relatively short amount of time. It is particularly well-suited for high-volume production of multiple identical units because the per-item setup and labor costs drop as production levels rise.
- Consistent accuracy and quality. Metal stamping can produce complex geometries with exceptional levels of precision and consistency, making it a perfect manufacturing choice for critical applications requiring extreme accuracy and tight quality control.
- Most aspects of the metal stamping process can be automated, which eliminates human error and also makes production substantially faster and more efficient.
- Metal stamping is an extremely versatile process that can be used with a variety of metal materials. This design flexibility makes it a good fit for meeting the unique demands of various lighting applications.
Where is Commercial and Industrial Lighting Used?
Commercial and industrial lighting solutions are used in creative ways to provide long-lasting, efficient, and reliable illumination for a variety of indoor and outdoor spaces. Metal stampings are an important component of these lighting solutions as they provide the housings and hardware necessary for recessing, focusing, or positioning the light in various ways to achieve the desired aesthetic or functional effect. The metal stamping process provides a way to manufacture high-strength and high-precision lighting components that can accommodate a range of lighting needs, from illuminating hospital operating rooms to enhancing architectural structures.
Some of the various ways lighting solutions are used in commercial and industrial spaces include:
- Department stores and other retailers rely on bright overhead lighting to simulate natural daylight. This helps to create a more inviting space that improves the overall shopping experience.
- For offices, lighting is used in ways that will enhance focus, alertness, and productivity. This includes being able to adjust the distance, position, or brightness level of the lighting to optimize the working atmosphere.
- Public buildings. Schools, universities, and government institutions use lighting to line hallways and walkways, illuminate lobbies, or enhance certain architectural features of the building. The number of lighting fixtures used, their positioning, and their level of brightness can vary significantly from room to room depending on the desired aesthetic or practical requirements of the space.
- Hospital lighting solutions are used differently throughout various areas to enhance patient wellbeing and staff performance. In operating or examination rooms, bright and functional lighting is important for keeping medical staff alert and optimizing visibility during critical medical procedures. In patient wards and waiting areas, lighting should be softer and less intense to create a comfortable and soothing atmosphere for patients and their family members.
Materials Used in Metal Stamping for Lighting
Part of what makes metals so suitable for the fabrication of lighting components is their durability and ease-of-use. Selecting the appropriate type of metal for a given lighting application is critical, as this will strongly influence the component’s aesthetics, longevity, and performance.
In general, metals with soft-to-medium hardness levels work best with stamping equipment for achieving high levels of precision. Non-ferrous metals, in particular, tend to fit the requirements of many lighting applications. Unlike ferrous metals, these metals do not contain significant levels of iron and are more corrosion-resistant and lighter in weight.
The most common metals used for stamping include steel, stainless steel, aluminum, copper, nickel, and brass. The reflective surface, durability, and strength of these metals make them a great choice for many lighting applications. However, certain specialized applications may require rare features that can only be found in exotic materials such as Inconel, Kovar, or titanium. The best metal material for a given lighting project will ultimately depend on the functional or aesthetic goals of the space as well as the type of environment it will need to withstand.
Examples of lighting components fabricated using the metal stamping process include:
- Shields
- Ring reflectors
- Covers and backplates
- End caps
- Clips
- Brackets
- Wire forms
- Springs
- Mounts
Precision Metal Stamping From American Industrial
Precision metal stamping is a versatile metal forming process suitable for fabricating parts with varying geometries and complexities. The consistency, accuracy, and cost efficiency of metal stamping make it a popular manufacturing choice for a wide range of industrial, commercial, and residential lighting applications. Another benefit of metal stamping is its ability to accommodate a wide range of materials, making it well-suited for meeting the aesthetic and/or functional needs of diverse lighting projects.
Established in 1981, American Industrial Company is a custom manufacturing company specializing in precision, high-quality metal stampings and assemblies. We are highly experienced in a variety of stamping techniques, including:
- Forming
- Blanking
- Bending
- Progressive
- Piercing
- Coining
- Shallow draw
Our engineering expertise, flexible manufacturing capabilities, and wide material selection allow us to meet the diverse needs of customers serving lighting applications and many other industries. From designing and prototyping to delivery of the final product, our skilled design and engineering team works closely with customers to develop and perfect each lighting solution according to the unique visual and practical requirements of the application.
To learn more about our custom-engineered lighting solutions and other manufacturing and design capabilities, please contact us today.
