Durable sealing of lighting fixtures for demanding environments
Lighting fixtures for outdoor, industrial, and public applications must withstand moisture, dust, UV radiation, temperature fluctuations, and vibrations. The tightness of housings and covers directly affects the durability of the fixture, the stability of the light output, and operational safety. Even a minor leakage can cause fogging, corrosion, and damage to the electronics.
MAE TECH offers automated solutions for applying gaskets and adhesive systems on lighting housings and covers. The FIPFG (Foam-in-Place Gasket) technology enables the creation of seamless gasket contours directly on the product — around lenses, glass covers, lids, and mounting panels. This ensures full compliance with IP65–IP68 requirements and eliminates the human factor.
Our systems operate with polyurethane foams, silicones, and MS polymers that are resistant to UV radiation, moisture, and temperature fluctuations. To improve adhesion, surface pretreatment such as plasma activation or primer application can be used. Precision servo-driven dispensers guarantee clean joint geometry and high repeatability, even in large-scale production.
Repeated opening and closing of the housing panels of heating, ventilation, and air conditioning systems, as well as service doors, is possible while maintaining a constant sealing effect
Automation reduces the number of defects, increases the reliability and durability of lighting fixtures, lowers maintenance costs, and enhances product competitiveness in international markets. MAE TECH solutions are easily integrated into production lines and can be scaled for various types and series of lighting — from compact LED modules to large industrial luminaires.
Technological challenges
Technology comparison table
Criterion | MAE TECH machines for gasket / adhesive application in lighting production | Manual gasket / adhesive application |
| Dosing accuracy | Precise and uniform material application with full control of bead width and volume | Depends on the operator; risk of uneven application and material waste |
| Tightness and IP protection | Repeatable, seamless sealing ensuring high ingress protection (IP) | Uneven sealing, higher risk of leakage and IP certification issues |
| Joint quality | Stable bead, high strength, and long-lasting joints | Lower repeatability and strength; variation between batches |
| Productivity | High process speed and automation, reduced assembly time | Limited speed, more time and manual labor required |
| Waste and defect reduction | Minimizes defects and human error | Higher risk of mistakes, frequent rework, and material waste |
| Aesthetics and appearance | Smooth, clean sealing contour, modern product look | Possible smudges, visual inconsistencies, less aesthetic finish |
| Workplace safety | Limited operator contact with chemicals | Greater exposure to adhesives/sealants, increased health risks |
| Material efficiency | Optimized use of adhesives and sealants, lower material costs | Overconsumption of materials and higher expenses |
| Process stability | Consistent process and uniform quality in every batch | Higher emissions and more waste generated |
| Environmental impact | Reduced VOC emissions and waste, compliance with environmental standards | Higher emissions and more waste generated |
| Labor cost | Higher initial investment, but lower labor and material losses | Lower initial cost, but higher operating expenses and defect rate |
| Setup and changeover time | Fast reconfiguration between products and materials (machine memory) | Time-consuming manual preparation and tool cleaning |
