9-Step Manufacturing Process
Raw Material Selection
Aluminum is a type of raw material rod and tube that comes to mind. Because the led flashlight will have an anodized aluminum body, the first step is ensuring that the raw material meets the hardness and other requirements. Once that's done, we start from scratch by milling the raw materials to create a basic flashlight prototype.
Customized Torch Shape
The metal bar is put into a computerized machine where the basic shape of the flashlight is milled out. This is followed by lathe operations for threads and bezels. We then work on finer details:
- Milling out custom shapes for the head and tail cap
- Machining any other custom features
Internal Drilling
We move on to drilling the interior of the flashlight to create channels that house the components. The aluminum body is cooled via coolant to avoid warping. Channels house the:
- LED
- Driver
- Switch
Thread Cutting
Threads are cut on the torch neck and the tail end where the battery cap screws on. The machine automatically makes both cuts precisely. We use high-quality metal to make a strong, durable bezel that protects the lens and frame from damage.
Anodizing Coating
A protective coating is sprayed on the inside and outside. This hard anodizing (Type III) protects from scratches, dents, and corrosion while making the flashlight resistant to dirt and grime. The surface can also be polished or buffed for aesthetics.
Logo Engraving
This step is usually done with a precision laser machine. After the logo is engraved, we attach the head and tail cap (made of steel or aluminum) onto the body, ensuring they are screwed tight and won't come loose during operation.
Switch Wiring
The switch (plastic or metal) is inserted into the body and wired to the LED and driver. This is a delicate process done by hand by skilled workers to ensure reliable electrical connectivity under stress.
Battery Assembly
We move on to inserting the batteries into the battery cap and screwing it onto the flashlight body. Functional tests are immediately performed to check light operation. Any units failing this check return to the inspection line.
Packaging
Final finishing includes adding clips, lanyards, or mounts. The flashlight is placed into its box with instructions and warranty paperwork. The box is sealed and prepared for shipment to the customer.
From
Flashlight Prototyping
To Production
We source quality raw materials and accessories and are mindful of the cost and time spent on production. Once everything we need is in place, we develop a mold for the prototype design, which captures the final appearance of our products. This consistent attention to detail ensures functionality when we begin manufacturing parts.
Rigorous Quality Control
Our ISO9001 certified laboratory performs comprehensive testing on every batch. Learn about our testing standards including Lumen output, IPX Waterproofing, and Impact Resistance.
View Quality Standards