Case Snapshot
Client Background
The customer was a USA LED lighting manufacturer developing high bay fixtures for industrial and warehouse lighting applications. Their design used the Bridgelux Vero 29 Array Series as the main light source, so the heatsink and reflector structure had to match the LED array’s mechanical and thermal requirements. The customer also needed product variation for different installation scenes, including body color, reflector material, beam angle, and suspension method. This made a standard heatsink or housing unsuitable for the project.
Visual Documentation
Customization Scope
LED Array Match: Heatsink structure customized for Bridgelux Vero 29 Array Series.
Body Color: Grey and black housing options prepared for product line flexibility.
Reflector Options: Aluminum and acrylic reflectors matched to different fixture needs.
Beam Angles: 45°, 90°, and 120° reflector options supported application variation.
Mounting Method: Chain-and-hook or ceiling pole suspension designed for installation flexibility.
Engineering Approach
VST Lighting provided a customized high bay heatsink and supporting fixture component structure for the customer’s LED high bay development. The work focused on component compatibility, thermal structure, reflector matching, surface finish, and mounting flexibility. The heatsink was developed to match the Bridgelux Vero 29 LED array position and fixture assembly requirements. Body color options were prepared in grey or black to fit the customer’s product line. Reflector choices included aluminum and acrylic, allowing the customer to cover different optical and appearance needs. For aluminum reflectors, VST supported polished or diamond-processed surfaces. Reflector beam angle options were prepared at 45°, 90°, and 120°. Mounting options included stainless steel chain and hook suspension, or pole suspension with a ceiling disc. Samples were used to confirm structure fit before production.
How We Delivered
VST reviewed the LED array model, fixture structure, reflector needs, color options, and mounting methods.
The heatsink, reflector interface, and suspension connection were developed around the Vero 29 array.
Aluminum, acrylic, polished, diamond-processed, grey, and black options were checked for production feasibility.
Custom tooling was prepared for the heatsink and related high bay fixture component structure.
Samples were checked for LED array fit, reflector assembly, surface finish, mounting parts, and appearance.
Production followed the approved samples, tooling references, material options, and confirmed configuration list.
Results & Outcomes
The customized heatsink gave the LED manufacturer a practical component platform for high bay fixture production. It allowed the customer to match the Vero 29 LED array while offering different reflector, color, and mounting configurations from the same development direction. The case helped reduce separate sourcing work for heatsink, reflector, and suspension parts. It also made the customer’s fixture range easier to configure for different industrial and warehouse lighting projects. By confirming tooling, samples, and component references before production, the customer had clearer control over repeat orders and product variation.
LED Compatibility: Heatsink matched Bridgelux Vero 29 Array Series requirement.
Reflector Angles: 45°, 90°, and 120° options prepared.
Reflector Materials: Aluminum and acrylic versions supported.
Mounting Options: Stainless steel chain-and-hook or ceiling pole suspension available.
Product Variation: Grey and black body color options prepared for fixture range.
Risk Assessment
300 pcs
About 4 weeks for tooling and sample preparation; about 20 days for mass production after sample confirmation.
VST Lighting supported samples to confirm the Vero 29 LED array fit, heatsink structure, reflector assembly, body color, aluminum or acrylic reflector choice, beam angle, and suspension method. Sampling was important because the component set had to support thermal, optical, mechanical, and installation requirements before bulk production.
After approval, repeat supply was controlled through confirmed drawings, approved samples, tooling records, reflector material references, surface finish requirements, and mounting accessory specifications. For future batches, any change in reflector angle, surface process, body color, or mounting hardware needed confirmation before production.
Full Case Notes
A USA LED lighting manufacturer customized a high bay heatsink to match the Bridgelux Vero 29 Array Series for its high bay fixture development.
The customer needed a thermal and mechanical component that could support its LED array, reflector selection, body color options, and different suspension methods. A standard high bay housing was not flexible enough because the fixture design required multiple reflector angles, different reflector materials, and mounting choices for industrial and warehouse applications.
VST Lighting developed a custom high bay heatsink and housing-related component set around the customer’s LED light source requirement. The design considered the Vero 29 array mounting position, heat dissipation path, reflector fixing method, surface color, and suspension structure.
The body was prepared in grey or black. Reflector options included aluminum or acrylic. The aluminum reflector could use polished or diamond-processed surface treatment, with beam angle options of 45°, 90°, or 120°. Mounting could be suspended by stainless steel chain and hook, or by a ceiling-fixed pole with disc.
Tooling took about 4 weeks, and mass production lead time was about 20 days after confirmation. MOQ was 300 pcs.
Technical Confidence
Certifications
Related Standards
EN61000
Notes
UL Compliance
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