BKLite Stage Light Factory Production Process

1. Material Preparation

Source high-quality LEDs, lenses, motors, power supplies, and other components from certified suppliers. Choose durable material for the housing (e.g., die-cast aluminum, flame-retardant plastic), DMX/RDM controllers, power supplies, and cooling systems (fans/heat sinks). Ensure cables and connectors meet safety standards. Source motors for pan/tilt mechanisms, gobo wheels, and color wheels. Verify precision in glass lenses and reflectors for optimal light output. Inspect incoming materials for defects. Test electronic components (e.g., driver boards, wireless modules) before assembly.

2. Product Production

Mechanical Assembly: Assemble housing, install heat sinks, and secure internal frames. Mount motors and mechanical components.

Optical System Integration: Align lenses, reflectors, and LED modules for uniform beam distribution. Calibrate color-mixing systems (RGB/CMY) and prism effects.

Electronics Installation: Solder and install PCBs, power units, and control interfaces. Connect wiring harnesses with strain relief to prevent disconnection.

Software & Firmware: Flash firmware with the latest DMX profiles and control protocols. Test wireless connectivity (Wi-Fi/Bluetooth) if applicable.

Final Assembly: Seal housing with gaskets for IP-rated models (e.g., IP65 for outdoor use). Attach branding labels, safety certifications, and serial numbers.

3. Product Testing

Verify DMX512/RDM responsiveness and smooth dimming transitions. Test color accuracy and strobe effects. Run continuous operation to check thermal management. Conduct electrical safety tests (insulation resistance, leakage current). Evaluate control software (e.g., mobile app, console compatibility). Ensure quick lens/gobo changes for live event setups.

4. Product Packaging

Carton case & flight case. Use molded foam inside, and reinforce corners with edge protectors for heavy units (e.g., moving heads). Before packing, make sure that cables, plugs, clamps, safety ropes, user manuals, etc. are placed properly.

  

This structured workflow ensures stage lighting products meet durability, performance, and safety demands for professional use.