Industrial LED Grow Lamp

Responsibility for the thermal solution, internal packaging, structural support, and overall mechanical design was given to Boyd.

The design had to meet safety-rating requirements for a moist environment with active sprinkler systems. It also had to be quiet and able to be hung from overhead supports.

The design had to compete on both cost and product life in a fast growing market.

Boyd worked closely with the customer’s team to generate concepts, design the product, source components, and fabricate prototypes of the first generation device.

The cooling airflow was routed through the heatsink to cool the LEDs and then through the second chamber to keep the LED drives cool.

The thermal performance of the system was designed so both the LEDs and the drivers are kept cool enough to exceed the 10 year product life target.

To minimize weight, the product design used the heatsink as the mechanical backbone of the system. This crated a structurally sound product and eliminated the need for any sort of frame, supports or extra bracing.

Specialized sheet metal locking mechanisms and extruded thread features were designed into the heatsink, which eliminated the need for excess machining and hardware. Boyd’s experience with manufacturing process meant we could add design details that reduced the cost of material, component manufacturing and assembly.

Boyd provided the customer initial prototypes, conducted system level testing to verify the thermal performance of the design.

As the design progressed to the production-ready stage Boyd helped the customer prepare for high volume manufacturing, including help them identify suppliers.

Boyd provided turnkey design services to a start-up company which enabled them to bring their product to market without the need to staff their own design department. Boyd and the customer are now working together on concepts for a smaller product for the home market.