Bending LED Light Extrusion Profiles

When planning LED light manufacturing, the first consideration is which design features make bending LED light extrusion easier.
If the LED light extrusion design cannot be changed, what can we do to improve its bendability?

Enhancing Bending Stability for LED Light Extrusions

Like other bending aluminum profiles, LED light extrusion is typically a U-shaped channel with a highly asymmetric design. This asymmetry causes significant torsional forces during bending, leading to the side legs twisting toward the channel’s centerline.

Structural Modification for Improved Bending

To address this, we can modify the LED light extrusion’s structure to correct the severe asymmetry. This adjustment reduces torsional stress during bending. Below is a case where we successfully bent an LED light aluminum extrusion for a customer, effectively eliminating the negative effects of bending.

Preventing Twisting with a Temporary Connection Piece

As shown in the image, the bent LED light aluminum extrusion remains free from twisting. The solution was to add a temporary, removable connection piece at the channel’s opening, as illustrated in the following gallery. This structural enhancement improves stability during bending and prevents deformation. Once bending is complete, the connection piece is removed.

Considerations for Assembly and Clearance

Another key consideration in bending LED light extrusions is their intended fit within an assembly or their ability to move freely inside a housing. Therefore, design specifications must include clearance tolerances to ensure proper installation and functionality.

When Modifying the LED Light Extrusion Structure Is Not an Option

In reality, modifying the structure of an LED light extrusion is not always feasible. Various factors may prevent any major changes to its design.

For aluminum LED light extrusion bending, the PBA aluminum bending machine is a large-radius profile bending solution. Additionally, BIT engineers provide technical support by designing internal support profiles for customers. These supports are typically made from polymer materials and help maintain stability during bending.

As shown in the two videos in this article, both cases utilized internal support profiles. Notice how the internal support ensures sufficient symmetry in the LED light extrusion, effectively eliminating the significant torsional forces that negatively impact aluminum bending.

About Curved LED Profiles

Curved LED Profiles are designed to protect and enhance LED strips while maintaining a sleek appearance. Their unique curved shape offers a smooth, seamless finish, ideal for spaces requiring a refined lighting touch.

These profiles are bendable, making them perfect for illuminating curved surfaces like pillars, arches, and walls. Their flexibility supports various lighting designs, such as cove, arc, and S-shaped lighting.

Additionally, Curved LED Profiles help dissipate heat, extending the life of LED strips. They are ideal for both indoor and outdoor projects, providing endless possibilities for creative lighting solutions.

PBA LED Lighting Bending Machines

The PBA aluminum bending machine offers unparalleled precision for shaping Curved LED Profiles. It excels in handling Single Curves, Complex Multi-Arc Shapes, Reverse Bends, and End-to-End configurations, ensuring versatility in lighting design. With its advanced control system, the machine delivers smooth and consistent results, maintaining the structural integrity of the aluminum profiles.

Whether you’re creating simple curves or intricate multi-arc shapes, the PBA machine allows for accurate adjustments to match various design needs. Its ability to perform reverse bends and achieve seamless end-to-end connections makes it perfect for challenging architectural projects.

This flexibility makes the PBA aluminum bending machine an essential tool for lighting professionals, enabling them to create unique, fluid lighting solutions for both indoor and outdoor applications.