Custom Rechargeable Waterproof LED Tube Light
An Australian electrical contractor needed a custom rechargeable waterproof LED tube light for wet, outdoor, farm, aquaculture, temporary lighting, and backup lighting…
View Case
Component Customization Case
Project Lighting Case
Commercial Lighting
Industrial Lighting
Office Lighting
Retail Lighting
Custom Aluminum Reflector for LED Tube Fixture
Case Snapshot
- Buyer Type
- Electrical Contractor LED Manufacturer
- Application
- Commercial Lighting, Industrial Lighting, Office Lighting, Retail Lighting
- Published
- May 5, 2026
Client Background
The project context behind the customization.
The customer was a Belgian electrical contractor working with LED tube light fixtures for commercial lighting projects. The contractor needed a reflector that could improve light distribution without changing the main fixture concept. The application required better use of LED tube output, a cleaner fixture appearance, and repeatable installation quality. Because the reflector had to match the fixture size and bending shape, a standard aluminum reflector was not enough for this project.
Visual Documentation
Project gallery
Customization Scope
What we customized and why it mattered
Key Custom Points
01
Wing Bending: 4.5mm bending diameter processed to match the fixture structure.
02
Reflective Surface: High-reflectance aluminum selected to improve usable light output.
03
Fixture Fit: Reflector profile customized to align with the LED tube fixture body.
04
Appearance Upgrade: Inner reflector shape improved the visual finish of the fixture.
05
Tooling Control: Custom tooling prepared for repeatable reflector bending in production.
Why This Approach Worked
Engineering Approach
Solution provided
VST Lighting provided a customized aluminum reflector for the customer’s LED tube light fixture. The solution was based on deep component and fixture-related customization because it required tooling, accurate bending, and surface material selection. The reflector was designed with a narrow wing bending diameter of about 4.5mm to match the fixture structure. VST reviewed the reflector profile, bending radius, aluminum thickness, surface reflection requirement, fixture assembly position, and visual finish before sample preparation. The aluminum reflector surface was selected to support high light reflection and better use of LED tube output. The customized shape helped direct more light toward the working area while also improving the internal appearance of the fixture. After sample checking, the reflector specification was confirmed for mass production with controlled bending shape and surface consistency.
How We Delivered
Delivery process
01
Requirement Review
VST reviewed the fixture structure, reflector shape, light output target, and appearance requirement.
02
Reflector Design Check
The bending diameter, aluminum surface, profile width, and fixture fit were evaluated before tooling.
03
Tooling Preparation
Custom tooling was prepared to form the narrow reflector wings with repeatable bending control.
04
Sample Confirmation
Samples were checked for fixture fit, reflection effect, bending shape, and visual appearance.
05
Mass Production
Production started after sample confirmation using the approved reflector profile and material reference.
Results & Outcomes
What the buyer gained from this custom project
The customized aluminum reflector helped the customer improve both optical efficiency and fixture appearance without redesigning the full LED tube fixture. By concentrating the tube light output, the fixture used more of the emitted light in the intended direction. The project result showed around 20% higher usable light output in the application and supported about 15% energy saving compared with the previous fixture setup. The controlled bending process also helped the reflector fit consistently during assembly. For the contractor, the main value was a practical component upgrade that supported project performance, fixture presentation, and repeat order supply clarity.
Light Output Use: Usable fixture light output increased by around 20%.
Energy Saving: Application-level energy saving improved by around 15%.
Bending Detail: Reflector wing bending diameter controlled at about 4.5mm.
Fit Result: Reflector matched the customer’s LED tube fixture structure.
Sample Status: Tooling samples confirmed before mass production.
Risk Assessment
Commercial risk overview
Moq
1000pcs
Lead Time
About one month for tooling and sample preparation; about 20 days for mass production after sample confirmation.
Sampling Support
ST Lighting supported sample preparation to confirm the reflector profile, 4.5mm wing bending diameter, aluminum surface reflection, fixture assembly fit, and appearance inside the LED tube fixture. Sampling helped the customer check whether the reflector improved light concentration before moving into mass production.
Supply Stability
After approval, VST used confirmed drawings, tooling references, aluminum material requirements, surface finish records, and approved samples to control repeat production. For follow-up orders, stable supply depends on keeping the same bending process, material grade, packaging method, and change communication before production.
Full Case Notes
Custom Aluminum Reflector for LED Tube Fixture
A Belgian electrical contractor customized an aluminum reflector for an LED tube light fixture to concentrate light output and improve fixture appearance.
The customer wanted the LED tube fixture to use more of the available light output instead of losing light inside the fixture body. The reflector also needed to make the fixture look cleaner and more suitable for commercial installation. A standard reflector profile was not suitable because the fixture design required narrow wing bending and a high-reflectance aluminum surface.
VST Lighting supported a custom reflector based on the customer’s fixture structure and optical target. The key processing challenge was the small 4.5mm bending diameter on the reflector wings. This required accurate forming control to keep the reflector shape consistent and avoid visible deformation during assembly. The aluminum surface also needed a high reflection effect to increase light utilization.
After tooling and sample confirmation, the customized reflector was prepared for mass production. The project achieved around 20% higher usable light output and supported about 15% energy saving in the fixture application. Tooling took about one month, and mass production lead time was about 20 days after confirmation.
More To Explore
Connected resources and similar cases
Similar Custom Cases
View All Cases
Custom T8 LED Tube with G5 Pins for Supermarket Lighting Project
A European electrical contractor customized a T8 LED tube with G5 pins to retrofit existing T5 fluorescent fixtures in a supermarket chain…
View Case
Custom Pink T8 LED Tube for Food Presentation Replace Natura
A Spanish electrical contractor needed a custom pink T8 LED tube to replace Osram Natura T8 fluorescent tubes in food presentation areas.…
View CaseStart A Similar Project
Need custom LED lighting for your market or project?
Send your application, target market, standards, quantity and special requirements. Our team can help evaluate the right custom path before production.