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Potting plant for polyurethane potting

Since 2017 we have been casting our lights with an in-house CNC casting machine. The system made for us guarantees a reproducible, high-quality, transparent polyurethane encapsulation (PU encapsulation) for our lights. The two components of the PU casting compound are sucked out of 60kg barrels into the plant's own stainless steel containers before the actual casting. In these containers, the two components are subjected to a strong vacuum, so that any moisture that may have been bound in the masses outgass. This enables transparent PU encapsulation free from disruptive microbubbles.

The mixing ratio of our PU is 1:1. This is particularly advantageous when applying very small dosages. The dosing head is controlled via a computer interface. In addition, it is possible for us to control the dosing manually, for example for the casting of special lights.

We cast our NauticProfile system (NP system) on tables using a precise 3-axis linear robot. This enables us to have a reproducible, consistent quantity and quality with every NP LightInsert.

FLASHAAR® Premium Coating


To protect against moisture, dust, vibration, mechanical stress and other harmful environmental influences, we have been casting our lights with a transparent polyurethane for many years. Until now, it was not possible to supply exactly the same color coordinates for indoor and outdoor areas, or for encapsulated and non-encapsulated luminaire inserts.

We have always carefully evaluated the optical properties of our resin to ensure that our PU preserves the color properties of the LED as much as possible. However, when measuring the color temperatures of the LEDs after encapsulation, we found that there is a shift in the color temperature. It drifts from a warm to a cooler color location. The higher the color temperature of the LED before encapsulation, the greater the color drift.

Premium Coating Inserts

With our conventional PU cover potting, the light is only emitted after penetrating the PU.
This leads to the undesired, clearly visible color locus shifts. Responsible for this is the change in the refractive index at the transition from the phosphor layer in PU instead of in air as before. Our PremiumCoating is simple and ingenious at the same time.
Before PU encapsulation, we clip the length of the new IP ProtectionCover over our high-quality LED aluminum core circuit boards. This minimalist cover covers the LEDs and thus prevents direct contact with the casting resin or our PU. The refractive index is unchanged, the color locus is constant. The luminaire inserts cast using FLASHAAR® PremiumCoating are also optimized for the combination with white colored covers.
An absolutely homogeneous, uniform linear appearance is guaranteed with this technology.

What is the difference between polyurethane and silicone?

Polyurethane and silicone are both synthetic materials, but they have different properties and uses.
Polyurethane is a thermoplastic that is made by reacting polyol and isocyanate. It is resilient, impact and abrasion resistant and is widely used in applications such as furniture upholstery, foam parts and coatings. Silicone, on the other hand, is an elastomeric material made from silicon, oxygen, carbon and hydrogen.
It is heat resistant, chemical resistant and has good electrical insulation. It is commonly used for applications such as gaskets, gaskets and components in electronics. In summary, polyurethane tends to be used in applications where resilience and impact resistance are important, while silicone tends to be used in applications where heat resistance and chemical resistance are important.

Why are LEDs potted with polyurethane? LED lights are often encapsulated with polyurethane (PU) to protect and insulate them. Here are some of the reasons why PU is suitable for this application:

  • Elasticity: PU is an elastic material that gives the lights a certain flexibility to absorb shocks or vibrations.
  • Shock Resistance: PU is a highly shock-resistant material that provides the LED lights with extra protection to avoid damage from shock or shock.
  • Insulation: PU has good insulating properties, which means it absorbs electrical noise and surges that could damage the LED.
  • Moisture Resistance: PU is moisture resistant, which is especially important when LED lights are used in humid environments.
  • Ease of Processing: PU is easy to mold and process, making it easier to cast around the LED lights for a perfect fit.
To sum up, PU is a good choice for LED light encapsulation because it has good protection and insulating ability, moisture-proof and easy to process.