Case Study – LED Engineering
When LED Engineering Wasn’t Enough,
C2S Delivered the Rest
Mechanical design, casting, thermal strategy, and environmental sealing:
C2S acted as Optec’s extended engineering team to bring a new high-bay LED product to market.
Problem
Optec, a leader in LED lighting, sought to expand into next-generation LED high-bay fixtures but lacked the mechanical design resources needed to manage complex engineering, thermal, sealing, and manufacturability challenges, risking delays and higher costs…
Solution
C2S led the full mechanical design and product development for Optec, creating a new cast aluminum housing optimized for modern LEDs, integrating electronics and thermal components, and prototyping to ensure performance, durability, and cost-effectiveness.
Outcome
The project successfully delivered a fully developed, production-ready high-bay lighting fixture, with C2S managing complete mechanical design and seamless integration, enabling Optec to confidently launch a competitive, U.S. made product on time, on budget, and with significantly reduced risk.
The Problem
Optec, a leader in LED lighting innovation, wanted to expand their product line with a next-generation LED high-bay lighting fixture. But there was a catch, they lacked internal mechanical and product design resources beyond their LED engineering team. Developing a high-bay light is complex, requiring a fully engineered housing, effective thermal management, environmental sealing, and cost-efficient manufacturability.
Without a partner to take on the full mechanical design effort, Optec faced increased risk, longer timelines, and challenges bringing a competitive, U.S. manufactured product to market at the right price point.
The Solution
C2S took full ownership of the mechanical design and product development, acting as an extension of Optec’s engineering team. Drawing on extensive experience in casting design and electronic integration, we designed a completely new cast aluminum housing optimized for an edge-lit lens and modern LED technology. After studying competing products, we developed a cost-effective design that met performance and market expectations.
Optec’s in-house lighting engineers designed the LED boards to our specified form factors, while C2S integrated the electronics, custom heat sinks, and electrical components into a cohesive system. We built and tested multiple prototypes to validate gasketing, water intrusion resistance, and overall durability.
The Outcome
The project resulted in a fully new high-bay lighting product developed from concept through production-ready design. With C2S handling the complete mechanical design and integration, Optec was able to enter the market with a competitive, U.S. manufactured fixture at a fair price point.
The partnership reduced development risk, accelerated time-to-market, and delivered a reliable, modern lighting solution that strengthened Optec’s product portfolio and competitive position.
Image courtesy of Optec LED Lighting.
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— Robert Kearns III, President C2S