The problem
A European client was looking to enter the North American market but needed to comply with UL1598 regulations, they required IC Boxes and related above-ceiling stamped metal components.
The original designs comprised two different IC Boxes and plaster frame sizes to facilitate the single and double lamp options. Upon reviewing the designs only the junction box, cover and bar hangers were the same on both; the plaster frames and IC Boxes were completely different. To make what was requested it would have involved designing & manufacturing 7 new dies, for a total cost close to $100,000, plus over 20 weeks lead time.
Tripar always strives to see if our standard parts can replace those custom designed in order to reduce cost and lead time for the client. We established that we had standard products; in this case, an IC Box whose size was remarkably close to the client’s design, and a standard plaster frame in which the either a single or double oval cut-out could easily be introduced at very low cost.
Recessed lighting assemblies
The solution
To save on new tooling costs, we recommended using Tripar’s standard lighting parts:
- 1685-11 IC Box, same one used for both designs
- 1286 plaster frame, same progressive die stamped base frame but with laser cut holes
- 1242 junction box cover, designed to fit with 1685-11 IC Box
- 1287 bar hanger set, designed to slide into 1286 plaster frame
Samples were submitted to the customer which easily passed the prescribed airflow test.
The results
In July 2021, the client ordered 3,000 units within a 4 week timeframe.
- Saved $100,000+ in tooling costs
- Used Tripar’s standard IC boxes and assemblies
- Customized the plaster frame holes (additional cost)
Since then, Tripar has produced tens of thousands of parts for this client.
IC assembly designs
Single lamp option
Double lamp option
Custom 1865 series assembly
