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| MANUFACTURING |
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| DESIGN |
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| Sunlight Supply, Inc. uses the latest 3-D CAD software to design all fixtures and reflectors in-house. Sophisticated photometric software ensures proper light dispersal. |
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| PUNCH |
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| TrumpI computer numerically controlled (CNC) punch presses are used to process steel and aluminum sheet metal for our reflectors and housings. |
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| BEND |
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| 6 TrumpI CNC press brakes are used to bend and form flat sheet metal. Exact tolerances of these new machines ensures bend tolerances to within 1/10 of 1% on every angle. |
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| PEM Inserts |
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| Specialized machinery presses in nuts and bolts called PEMS. These fasteners are used to mount ballasts, sockets, grounding wires, air-cooled fittings and simplify the assembly process. |
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| RIVET |
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| 5 automatic feeding rivet machines are used to fasten sheet metal parts together. We use only "button hand" style rivets which are flush mounted and contain no unsightly hole on the backside. |
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| Powdercoat |
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| A powdercoat finish is given to all our reflectors and ballast housings. It is an electrostatic process where by the powder, ususally white, black, blue or green, is applied to a part. Powder has the look and feel of baking soda but is far more durable and corrosion resistant than liquid paint. |
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| The part is hung from a conveyorized line and enters a 5 stage wash where heated and chemically treated water cleans the part. |
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| The cleaned part is dried and then enters a spray booth where the powder is applied. 8 guns shoot powder from different angles to completely cover the part. Human touch-up is done at the end of the spray booth. |
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| The part enters a combination oven which uses infra-red and convection heat to cure the powder onto the part. After, it enters a "cool down" area prior to handling. |
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| ASSEMBLY |
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| Sunlight Supply completes final assembly of all remote reflectors in our Woodland, WA, facility. All ballast fixtures both HID and fluorescent receive final assembly in our Vancouver, WA, plant. |
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| TESTING/QC |
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| All Sunlight Supply fixtures are tested 4 ways. Every fixture is test-fired twice from 2 different people. It must pass a Hi-Pot test for grounding, electrical leakage and a di-electric test. The overall product is reviewed for fit and finish labeling, all fasteners tight, sockets secure, etc. |
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| PACKAGE |
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| All finished products are then boxed and sent through taping machines for closure. |
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| TRANSPORT |
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| Products are then transported to 7 distribution locations for shipment to our authorized dealer partners. |
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