Is it necessary to consider the dimensional accuracy when selecting die-cast lighting parts?

When selecting die-casting lighting parts, dimensional accuracy is a core element that must be strictly controlled, which directly affects product functionality, production efficiency, and user experience. The following are key considerations:

1. Matching of optical parts
Lens/reflector positioning: Deviations in the coordination between the light source and optical parts (such as misalignment of more than 0.5mm) can cause spot distortion, glare, or uneven brightness.
Sealing failure risk: If the size error between the lamp shell and the waterproof rubber ring is too large, it will not be compressed tightly or squeezed excessively, causing water leakage (a fatal problem for outdoor lights).

2. Assembly efficiency and compatibility
Chain reaction of out of control tolerance:
Hole deviation → forced screw in → thread slipping or shell cracking;
Card slot size exceeds tolerance → circuit board cannot be inserted → production line shutdown for rework.
Modular design failure: When replacing spare parts, they cannot be interchanged due to size fluctuations (such as customized parts for street lamp maintenance).

3. Implicit correlation of heat dissipation performance
Uneven contact surface: When the gap between the die-casting part and the radiator is too large (>0.1mm), the thermal grease cannot fill the gap, causing a surge in thermal resistance and accelerating light decay.
Fin deformation: Demoulding deformation leads to uneven spacing between heat sinks, reducing airflow convection efficiency.

4. Structural safety and lifespan
Stress concentration point: At the point of sudden change in size (such as when the screw column is too thin), microcracks may occur due to insufficient accuracy, and the risk of fracture increases under vibration environment.
Metal fatigue: Frequent disassembly and assembly of parts with tolerances exceeding the tolerance limit can accelerate thread wear (such as loosening and detachment of wall lamp bases).

5. The Source of Cost Black Hole
Secondary processing cost:
Drilling/milling correction position → doubling of labor cost;
Full inspection and selection of defective parts → yield loss>10%.
The surge in after-sales costs: installation workers need to repair damaged parts on site before assembly → customer complaint rate increases.