BESPOKE SOLUTIONS
Where our comprehensive product range does not fully meet the requirements of a project, we will custom design solutions to ensure we provide the perfect solution for your installation. Bespoke solutions range from complete luminaires through to retrofit replacement trays to ensure that any project can be completed with the most cost effective product without compromising on quality or compliance.
Dextra Group have a long history of such collaborative projects with key clients who have commissioned bespoke solutions, some of which have gone on to be added to our standard product range. Our design and testing facilities include the latest 3D modelling and photometric design software, a state of the art testing laboratory with photometers, thermal test cages, EMC testing facilities and integrating sphere all operated by staff with decades of lighting expertise. This design and testing resource is combined with huge investment in SMT circuit manufacturing equipment, CNC and laser metalwork machinery, routers and 3D printing equipment. Our combined expertise and manufacturing capabilities allowing us to take your project from design concept to manufacturing rapidly, ensuring that the product meets both your expectations and deadlines without compromising performance or reliability. Where required we will also invest in bespoke extrusions, injection mouldings and die castings for custom commissions bringing a quality finish to your product that is entirely unique to yourself.
Our commitment to service goes far beyond the luminaire itself. We have a large resource of lighting experts based around the country who can visit your installation and advise on the optimum solution with consideration for lighting design, energy saving, legislative requirements and minimal cost of installation with your existing infrastructure. We provide a full service from initial site assessment, luminaire specification, quotation and payback calculations, dedicated contacts throughout the design and sampling process through to site delivery of products with our 5 year warranty and collection and recycling of old product removed from site.
A selection of bespoke projects from our catalogue are outlined below.
“Where required we will invest in bespoke extrusions, injection mouldings and die castings, bringing a quality finish to your product that is entirely unique””
Retail Raft
We worked in collaboration with a major UK retailer who tasked us with replacing existing fluorescent rafts across their stores with a brief to ensure that they achieved a substantial reduction in energy consumption, Co2 and ongoing maintenance, whilst also bringing a fresh and modern appearance to their estate. Several concepts were put to the client who settled on a design incorporating a continuously lit LED border framing a central downlight scoop array. The final design included a modified version of our popular Ineal range to create the continuously lit border, whilst the central array sat within a dropped panel to bring the centre and border to equal depth creating additional visual interest.
The Ineal border incorporates a baffled lens design providing state of the art efficiency with minimal glare ensuring that the retail space was effectively lit creating a desirable space for customers, whilst substantially reducing power consumption and the clients carbon footprint.
A key challenge of the project was to ensure that each raft could be replaced across the estate regardless of size, with designs varying from 900x900mm all the way up to 2400x2400mm in size with a range of central downlight option. This raised numerous design challenges and logistical challenges and the largest variants were designed in modular format to ensure that they could be easily handled both through the manufacturing process and for the installing parties.
Rubini Recessed 4/8/12
Developed in conjunction with a key retail partner, the Rubini Recessed 4 cell, 8 cell and 12 cell were originally developed to replace CDMT spot clusters across retail outlets in the UK and abroad. The project brief was to develop a highly efficient long life LED solution to replace existing luminaires with housings customised to suit the existing luminaire dimensions therefore minimising the need to modify the ceiling during installation, whilst offering substantial energy savings, minimising ongoing maintenance and also aligning with their store appearance with a discrete and minimalist design.
Our development work with the client involved creating a customised cellular baffle design with new injection tooling for both the bezels and LED cells in three sizes and a selection of surface finishes. Three bespoke LED circuit boards were developed for manufacture on our SMT lines to ensure that the lumen output was both comparable with the existing luminaires whilst offering substantial energy savings and eliminating the need for ongoing lamp replacement. This highly successful development has since been launched as a standard offer in our downlight range.
Vehicle Paint Line Inspection Luminaire
Developed for a prestigious UK car manufacturer, the paint line inspection luminaire was designed in conjunction with our client to allow detailed inspection of paint finishes to enable employees to identify and correct the smallest of blemishes. The luminaire combined diffusers of differing colour temperatures, these create contrasting reflected bands of light on the vehicle surface highlighting defects as employees move around the vehicle. The black front face ensures that only the light bands are reflected rather than the luminaire face minimising visual fatigue despite the high lux levels required.
To meet other areas of the customers specification the luminaire was designed with an IP44 construction to prevent ingress of paint dust where minor reworks are undertaken whilst the luminaire dimensions, bracketry and electrical connectors were customised to work in conjunction with the customers gantry system ensuring that installation was seamless.
Yard Arm
The Yard Arm luminaire was developed in conjunction with railway sector clients to offer a one for one replacement for luminaires used in sidings and maintenance areas. Bespoke die cast housings with custom gaskets and 6mm toughened glass covers were tooled for the client to provide a compact design capable of replacing the existing luminaires on a one for one basis reducing installation costs and ensuring existing infrastructure could be reused whilst also greatly improving efficiency and reducing maintenance costs.
A key aspect of the project was to ensure that the luminaire could work with the existing column out-reach arms and fixing mechanisms, the customised housing was designed to include identical mechanical fixing and cable entry points to replicate the original luminaire whilst custom gaskets for the mounting points were commissioned to ensure that the IP65 rating was maintained. Toughened 6mm etched glass was used on the front face of the luminaire with quarter turn screws for ease of installation and excellent weather resistance. To ensure that the luminaire provided an equivalent lumen output to the existing HID source a customised LED circuit boards was designed and manufactured on our SMT lines, whilst lighting designs and trial installations were undertaken to ensure that lux levels and uniformity would not be compromised in these safety critical applications.
Should you require a lighting solution that is not available in our standard product range please contact us for an initial discussion to see how we can assist with your project.
