Modern LED spotlights set new standards in professional lighting and are internationally regarded as the benchmark for lighting technology on demanding film sets. Lighting technicians and creative professionals choose this spotlight solution because of its reliable performance and versatility. Thanks to innovative manufacturing technologies such as laser plastic welding, the LED spotlights are also optimized for reliable use in all climatic conditions.
The current models from these lighting manufacturers feature modular LED lighting systems that can be flexibly adapted to different requirements in terms of size and performance. A key performance feature is their suitability for use in all weather conditions, supported by IP66 protection, which ensures reliable operation in a wide range of weather conditions.
When manufacturing these LED modules, the focus is on creating a durable and precise connection between the optics and the housing. The assemblies must ensure long-term stability in accordance with protection class IP66. In addition to reliable sealing, mechanical durability and protection of the precision optical elements are key requirements. The joining process must not impair the quality and function of the optical components.
Adhesive bonding and laser welding were initially evaluated as joining technologies. Laser welding was preferred due to its superior process reliability, short cycle times, and the ability to produce aesthetically high-quality, completely sealed joints. Compared to adhesive bonding, laser welding also scores points for its lower space requirements and lower operating costs, as no additional consumables are required.
Advanced quasi-simultaneous welding (AQW) is used, in which a galvanometer scanner guides the laser beam along the welding contour at speeds of up to 10 m/s. The combination of two laser sources with different wavelengths, which can be used individually or simultaneously, ensures optimum energy input and short process times. The simultaneous heating of both joining partners enables new material combinations and ensures increased strength.
Conclusion
The current generation of modular LED spotlight systems sets new technological standards in professional lighting. Laser welding of plastics in combination with state-of-the-art system concepts impresses in series production with a consistently stable and clean process. The high availability of the system, minimal follow-up costs thanks to low-maintenance laser sources and reliable components, and the robustness of the process chain meet the demanding requirements of film and media technology in terms of quality, precision, and efficiency.
