Reev

LED Lenses

LED Lenses

Reeves specializes in LED lenses; we have for 20 years. Consistently extruding lenses is harder than normal extrusion because any impurities, defects or variations are easily seen behind LED lights. Over the years, we built our culture and processes around being an LED lens supplier as our primary goal, rather than just another capability, or product line.

Our long history of making lenses also enables us to provide valuable insight on design for extrudability and fit with aluminum fixtures. We also blend thousands of formulations of different colors and compounds to hit specific light transmission and diffusion targets. We know what works and what does not. We also constantly search for new materials to increase the performance of the lens.

Here is a brief overview of our LED lens capabilities:

Process

We have two types of extrusion processes:

  • Mono: Only one compound per profile
  • Co-extrusion: Two compounds per profile

Formulations

We custom blend compounds and colors to achieve your targets
  • Compounds
    • Acrylic
      • Most frequently used in LED lenses due to clarity and performance
      • Types
        • Clear – Used in optical and Fresnel lenses
        • Frosted – Used to help hide the diodes. Our frosted materials also have similar light transmission to clear acrylic. They also have a textured finish.
        • Diffuse – Similar to frosted, but with a smooth texture. Diffuse can help hide diodes better than frosted, but can significantly decrease light transmission
        • Impact modified – Impact modified acrylic helps make the lens more flexible, which is important when snapping into the aluminum frame. Impact modified also helps prevent cracking and splintering overtime in outside applications. Impact modified acrylics are available in clear, frosted and diffuse grades.
    • Polycarbonate
      • Our polycarbonate is optical grade
      • Polycarbonate is much harder than acrylic, but can yellow over time especially in outside conditions
      • We have several UV and diffusion options we can blend with polycarbonate to help achieve light transmission and hiding power
  • Colors
    • We can add color or buy pre-colored material to hit your color targets
    • We’ve also developed proprietary colors that help improve performance, including:
      • Reeves White: Gives the lens a nice white glow when the LEDs are on and off. There’s no premium for this white, we just want you to have a nice lens.
      • Diffuse White: This helps reduce dark areas on the edge of lenses, or in corners
      • Highly Reflective White: Typically coextruded on legs, this helps improve light transmission with the added benefit of reducing dark areas on the edge of lenses or in corners
  • Blending
    • We custom blend colors and compounds to achieve your light transmission and diffusion targets
    • We custom blend compounds and colors for nearly every job we run
    • We thoroughly mix the batches in a mixing machine to ensure consistency throughout the batch
    • We precisely measure compounds and color to create batches of material. The precision allows us to achieve the same profile performance for each order
  • Regrind
    • We don’t use regrind in our lenses. Many extruders will reuse regrind to help save costs, but regrind introduces impurities into the lens and variability on performance.
    • We recycle about 95% of our waste back into our extrusions because we believe in playing our part in preserving our environment. We just use it in our other product lines.

    Shapes / Profiles

    We run several hundred different profiles each year. In general, we can run:
    • Width: Up to 24 inches
    • Thickness: 0.020 inches to more than 0.250 inches
    • Length: Typically range from 0.25 inches to 25 feet, though we’ve run longer pieces
    • Common Shapes / Profiles
      • Fresnel lenses
      • Batwings
      • Tubes
      • Squares
      • Collimators
      • C-Channels
      • Asymmetric flow, such as a thick lens and thin legs

    Tooling

    We’ve made our own tooling for 50 years

    • 50 years of experience (including mistakes) goes into every profile
    • Typical lead time for tooling is 4-6 weeks
    • Tooling pricing also includes first article samples

    Tuning

    Reeves has the tools and expertise to keep your dies running at speed and on spec

    • Die cleaning after every run
    • Wire EDM
    • CNC Mill
    • Surface grinders
    • Drill press, lathes, mills
    • Die storage in designated areas

    Capacity

    We have capacity and the range in machine sizes to extrude small and large profiles

    • 8 main extruders ranging from 2” to 3.5”
    • 2 co-extruders

    Inline Value-Add

    Our team is great at devising innovative ways to accomplish secondary operations in-line with extrusion

    • Cut to length
    • Sleeving
    • Boxing

    Fabrication

    We route, kit and assemble every day in our 40k ft warehouse

    • We have a team dedicated to in-house fabrication
    • Punching
    • Routing
    • Assembly

    Packaging

    We package to your specifications

    • Sleeving
    • Boxing
    • Palletizing

    Distribution

    We can arrange shipping, or coordinate with your carriers
    • Warehousing
      • Safety stock
      • Staging
    • Shipping
      • Truckload
      • LTL
      • FedEx / UPS

    Customer Service

    When you call, we pick up the phone

    • You will have a dedicated salesperson, as well as customer service representative
    • If you have a spike in demand, we can react within hours to change our production schedule to get you back in stock
    • If you have a quality issue, we launch our corrective action process to identify and implement solutions to eliminate the issue going forward

    Quality

    Reeves strives to drive a culture of continual improvement by pairing ISO9001: 2015 compliant processes with Lean Six Sigma methodologies
    • Inspection and Statistical Process Control
      • Quality personnel and operators check critical dimensions on the 1st piece, every hour, and last piece during the manufacturing process
      • We retain samples for one year to reference in case of escape
      • We also perform functional tests and cosmetic inspection
    • Nonconformances and Corrective Action
      • Nonconforming material moved to MRB area for root cause investigation and disposition
      • After determining root cause, we qualify the issue based on severity to determine whether we need to launch a Corrective Action Process. We close the corrective action report only after verifying the effectiveness of the solution
    • Lean Projects
      • We identify constraints and opportunities for improvement for potential lean projects
      • We review the list of potential projects and prioritize based on impact, time and feasibility
      • We utilize DMAIC and Kaizen tactics to drive positive change in our processes by eliminating waste and increasing repeatability

    New Product Development Process

    • Discovery
      • Discussion on the application and end use of the product, especially as it relates to mating parts
      • Preliminary discussion of capabilities required to achieve customer success criteria
    • Design Review
      • Engineering review of profile design, including printing 3D models if necessary
        • Reeves will provide design guidance on extrudability
        • Note: As we move to ISO 9001: 2015, ownership of product design will remain with the customer
      • Material and color selection, including samples
      • Inline value-add and fabrication review
      • Labeling, packaging, and transportation requirements
    • Proposal with pricing and lead times
      • Profile quotes by run size, color and compound
      • Tooling quotes, including first article samples
      • Inline value-add, including building custom equipment
      • Fabrication and kitting
      • Lead times
    • First Article Inspection (FAI)
      • Purchase orders start the process
        • Tooling
        • Raw materials (if not stock materials)
      • Test and tune tooling
        • Establish run conditions
        • Samples sent to customer
      • Quality
        • Establish quality documents, including critical dimensions
        • Ensure receipt of mating parts for fit testing
      • Confirm shipping configurations
        • Test ship parts if necessary
      • Customer approval
    • Production
      • Setup ERP and bill of materials (BOM)
      • Establish raw materials supply chain
      • Review customer forecast
      • Customer purchase order

    If you are interested in learning more, or getting started on a new project give us a call at 661.854.5970, or email sales@reevesextruded.com

    Contact Us

    661.854.5970