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Fabrication of a Light Aluminum Protection Cage for the Lighting Industry

Industrial Alloys, Inc. was contracted by a customer in the lighting industry to create the custom protection cage highlighted here. This cage would house stage lighting fixtures in a multi-use gymnasium/worship hall space, protecting the contents during sporting events. The cage featured remote operation via a switch, allowing both the front and back ends to open and close. Employing advanced machinery and tools, Industrial’s skilled professionals expertly utilized shearing, plasma cutting, sawing, and certified welding processes on 6061 expanded and tube aluminum and 5052 aluminum plate to achieve the specified contours. A tight tolerance of ± 0.0312" was maintained throughout. The unit was deburred to remove machining debris, and left with a mill finish. A 100% dimensional inspection was carried out to ensure the highest quality and accuracy standards were met.

Eight protection cages were fabricated for this project after a 3 week turnaround time, and shipped to the customer in Weddington, North Carolina. The standards required by the customer were met, as well as meeting the rigorous quality standards set by ISO 9001:2008. For more information about this custom light aluminum protection cage fabrication, or the other value added services available, please see the table below or contact Industrial Alloys directly.
Unit of Measure

Highlights of this Custom Aluminum Protection Cage Fabrication

Product Description

 N/A This cage is used to protect stage lighting fixtures and projectors for a church whose sanctuary is also used as a gymnasium. Cages were designed to allow the front and backs to be opened when the lights and projectors were being used and closed when there was a basketball/volleyball game being played so the equipment would stay protected. Cage doors were opened and closed by flipping a switch wired to a control room switch panel.

Primary Aluminum Fabrication Capabilities Applied/Processes

 N/A Plasma Cutting Sawing Shearing Welding

Secondary Aluminum Fabrication Capabilities Applied/Processes

 N/A Deburring

Equipment Used to Manufacture Part

 N/A Accurshear AKS Hi-Def Plasma Hem Saw Miller Tungsten Inert Gas (TIG) Welder

Overall Part Dimensions

 N/A Varies

Tightest Tolerances (±)

 N/A 0.0312 in

Material Used

 N/A 5052 Aluminum Plate 6061 Aluminum Expanded 6061 Aluminum Tube

Material Finish

 N/A Mill

In Process Testing/Inspection Performed

 N/A 100% Dimensional Inspection

Industry for Use

 N/A Lighting Fixture Industry

Volume

 N/A 8

Delivery/Turnaround Time

 N/A 3 week

Delivery Location

 N/A Weddington, North Carolina

Standards Met

 N/A CAD Drawings Customer Specifications

Product Name

 N/A Light Aluminum Protection Cage