Aluminum LED Housing Die Casting – High Thermal Conductivity & Lightweight Design
Material Options: ADC12 / A380 / AlSi9Cu3 / AlSi12Fe
Process: High Pressure Die Casting (HPDC)
Locking Force: ≤800 tons | Part Weight: ≤10 kg
Product Description
Our aluminum LED housing is manufactured by High Pressure Die Casting technology, specifically designed for LED street lights, flood lights, high bay lights, tunnel lights, and industrial/commercial lighting fixtures. The housing integrates the main body, heat sink fins, and mounting brackets into a single cast component, ensuring excellent thermal management, mechanical strength, and cost efficiency.
With 800 tons maximum clamping force, we produce LED housings weighing from 0.2 kg to 10 kg, covering small COB LED downlights to large 500W+ stadium floodlights. Each casting features optimized fin geometry for maximum heat dissipation, helping to extend LED lifespan and maintain lumen output.
Why Die Cast Aluminum for LED Housings?
| Property | Advantage |
|---|---|
| Thermal conductivity | 90–120 W/m·K (ADC12/A380) – rapidly transfers heat away from LED chips |
| Light weight | Density ~2.7 g/cm³ – 1/3 of zinc or brass, reduces fixture weight |
| Design flexibility | Complex fin shapes and thin walls (≥1.5 mm) possible with HPDC |
| Corrosion resistance | Natural oxide layer + optional powder coating for outdoor use |
| EMI shielding | Aluminum provides electromagnetic interference protection for drivers |
Available Alloys – Selection Guide for LED Housings
| Alloy | Thermal Conductivity | Castability | Corrosion Resistance | Typical Application |
|---|---|---|---|---|
| ADC12 | ~96 W/m·K | Excellent | Good | General LED housings, floodlights, garden lights |
| A380 | ~100 W/m·K | Excellent | Very good | High-power LED modules, automotive exterior lighting |
| AlSi9Cu3 | ~110 W/m·K | Very good | Good | Heavy-duty industrial LED fixtures (high temperature environment) |
| AlSi12Fe | ~120 W/m·K | Good | Very good | Thin-wall designs, corrosion‑prone outdoor applications (coastal areas) |
We recommend ADC12 or AlSi12Fe for standard LED housings – best balance of cost, thermal performance, and die life.
Technical Specifications (Typical for LED Housing)
| Parameter | Specification |
|---|---|
| Machine tonnage | 180T – 800T (matched to housing size) |
| Max housing dimensions | Up to 600 × 600 × 150 mm (depends on fin height) |
| Wall thickness (minimum) | 1.5 – 3.0 mm (fins as thin as 1.2 mm) |
| Fin aspect ratio (height/width) | Up to 8:1 (with proper draft angle) |
| Flatness tolerance | ≤0.3 mm on mounting surface (post‑CNC if required) |
| Surface roughness (as cast) | Ra 3.2 – 6.3 μm |
| Pressure tightness | No porosity visible; optional impregnation for IP65/IP67 sealing |
| Secondary operations | CNC drilling/tapping, deburring, shot blasting, powder coating, anodizing (clear or black) |
Key Features of Our LED Housings
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Optimized fin design – Our DFM (Design for Manufacturing) team helps improve fin density and airflow channels without compromising fillability.
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Porosity control – High‑pressure die casting with vacuum assist (optional) minimizes gas porosity, ensuring consistent thermal paths.
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Pre‑drilled mounting points – We can cast holes for PCB mounting, driver bracket, and lens screws – reducing secondary drilling.
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Surface finish options:
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As‑cast (natural aluminum)
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Shot blasting (uniform matte finish)
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Powder coating (black, white, grey, RAL colors)
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Anodizing (clear, black, hard anodizing for wear resistance)
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IP rating ready – Smooth gasket grooves can be cast directly for sealing rubber rings (IP65 / IP66 / IP67).
Production Workflow for LED Housing Orders
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Customer provides – 3D drawing (STEP/IGS), 2D tolerance sheet, and required alloy.
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Mold design & tooling – Steel mold (DIN 1.2344 / SKD61), typical lead time 25‑35 days.
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Sample casting – T1 samples (5‑10 pcs) for dimensional approval and thermal testing.
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Secondary machining – CNC milling of critical surfaces and holes (if required).
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Surface treatment – Powder coating or anodizing via our certified subcontractors.
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Quality inspection – CMM, X‑ray porosity check, thermal conductivity test (on request).
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Packaging & shipment – Individual foam/polybag protection, carton with pallet.
Quality Control Measures
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Incoming material – Spectrometer analysis for each alloy batch (ADC12, A380, etc.)
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In‑process – First article inspection (FAI), periodic sampling for porosity and hardness
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Final – 100% visual and dimensional check for critical mating surfaces
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Optional – X‑ray inspection for internal voids; pressure leak test for sealed housings
Why Choose Wuxi Hengzhihui for LED Housing Casting?
✅ Specialized in <10 kg aluminum parts – LED housings are our sweet spot.
✅ 800T max capacity – Enough for large LED fixtures (e.g., 1000W high bay).
✅ Four standard alloys in stock – ADC12, A380, AlSi9Cu3, AlSi12Fe – fast raw material sourcing.
✅ One‑stop service – Casting → CNC → coating → assembly → packaging.
✅ Quick response – Sample lead time as short as 20 days for simple housings.
✅ Export experience – We ship to Europe, North America, Southeast Asia, and Middle East.
Get a Custom Quote
Tell us your LED housing specifications (power, size, target thermal resistance, IP rating, annual quantity), and we will recommend the best alloy and process.
Contact: Alice Yuan
Phone / WhatsApp: +86 15106174543
Email: yjhtrade@gmail.com
Websites: www.hzhmetals.com | www.wuxihengzhihui.com
Wuxi Hengzhihui Metal Materials Co., Ltd. – Professional die caster of aluminum LED housings, heat sinks, and lighting components.
