Industrial Plastics for Lighting Applications

At BD Custom Manufacturing, Inc., we produce custom plastic extrusions for industrial and commercial LED lighting applications. Our high-quality products provide thermal performance, ultraviolet (UV) resistance, and precise optical control for fixtures used in warehouses, outdoor signage, commercial, and retail settings. All lighting plastics solutions are designed for long-term clarity with plastics that can withstand exposure to heat and UV radiation.

With years of lighting-specific extrusion experience and the capacity for small- or large-scale production, our team serves OEMs with custom products that meet their requirements. Learn more about our lighting extrusion products, their applications, and what sets BD Custom Manufacturing apart.

Common Lighting Extrusions

Our comprehensive lighting profile catalog includes LED channels, lens covers, and trim extrusions that integrate seamlessly into retrofit or new lighting fixtures. We have designs that accommodate flush-mount, surface, and recessed configurations with consistent clarity, functional geometry, and secure fit.

LED Channels / Lens Covers / Trim Extrusions

Extruded LED channels house lenses and strips in tight-tolerance configurations and include these features and options:

LED channels. These help extend LED service life by protecting them from debris and impact. They also assist with thermal management.
Covers. Options include frosted, diffused, and clear finishes to avoid hotspots and manage brightness levels.
Trim profiles. These help create seamless transitions at wall and ceiling mounting points.

Required Features of Lighting Extrusion Materials

Plastics used for lighting applications need to remain stable under UV exposure, retain clarity, and withstand heat without catching fire. This keeps the fixtures inside protected and maximizes transmission of light, which are important in industrial and commercial settings.

We use materials that meet these requirements and are suitable for printing, notching, and other secondary operations without damage.

Clarity / Heat Resistance / UV Stability

Acrylic and polycarbonate are both widely used for lighting applications. Acrylic lenses, LED channels, and tubes have excellent clarity and can be polished to a high shine. Acrylic is also very rigid and resists yellowing. Polycarbonate is more flexible and has greater impact resistance than acrylic materials. Polycarbonate remains stable in ongoing temperatures up to 120 ºC. These materials can also be UV-stabilized to retain their optical performance when exposed to the harsh conditions and outdoor environments.

Applications Across Industries

BD Custom Manufacturing makes lighting extrusions for a variety of workplace, outdoor, and industrial applications including, but not limited to:

Architectural lighting. LED channel profiles install seamlessly into wall accents and ceiling coves for visual appeal and a streamlined look in commercial and industrial facilities.
Display lighting. Diffused lens covers reduce glare in museum showcases and retail shelving.
Task lighting. Narrow-profile trims and diffusers are commonly used in industrial zones and offices to focus light on workstations.

Why OEMs Choose BD Custom Manufacturing for Extruded Lighting Solutions

BD Custom Manufacturing is a trusted supplier of custom extrusions for a variety of lighting fixtures. Our end-to-end services include:

Calibrated extrusion.
Design assistance.
Flexible production capabilities
Precision tooling.
Small batch manufacturing.

Short Runs and Precision Manufacturing

We maintain a library of standard tooling and extrusion dies in-house, and also have the ability to build custom dies or even use client-owned tooling. We create a set-up manual for each profile to ensure consistency and streamlined set-up for each project. Typical lead times for profiles in one of our 50+ stock colors are about ten working days from when an order is placed and the die is prepared. We support both small- and large-volume production for standard and custom profiles.

We are also committed to quality control throughout the manufacturing process. This includes random inline inspections and analyzing data gathered from production equipment. We verify profile shape, dimensions, and extrusion thickness to meet your requirements.

Contact Us for Your Next Lighting Profile Extrusion Project

Since 1993, BD Custom Manufacturing, Inc. has focused on serving small to mid-size clients with high-quality plastic extrusions. We provide standard and custom extruded lighting covers, LED channels, trims, and diffusers for OEMs and other businesses. Clients can choose from a variety of durable materials such as PMMA, UV-stable blends, and polycarbonate for a heat-resistant, clear, and mechanically stable solution.