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Special processing

Anodizing


Most of the profiles are anodized to avoid aluminum oxidation. The aluminum products we make are processed by certified companies, following the UNI 10681/2010 standards. For products used outdoors, the anodization is carried out in class 20, with a treatment thickness of over 20 microns, especially suitable for outdoor environments. Anodizing is a chemical process, therefore there could be impurities due to the reaction of aluminum, this does not denote a product defect but a technical characteristic. The advantage of this process is the possibility of painting the product with enamel.

         

Custom LED bars


Dogi Group decides to face a challenge, adding to its assets a precision machine for cutting aluminum allowing to compose bars from a few centimeters in length up to a maximum of 4m, for the most popular models. Furthermore this machine gives the possibility to cut the ends of the profile at any angle allowing to transform a simple bar into a real design element. Another key to aluminum is finishing. The classic anodized gray and white were not enough at all for the product to integrate into any type of environment, so we developed and implemented our network of specialized contractors in galvanizing and painting to allow the customer to finish and transform the aluminum bar and insert it in any context. The last major innovation concerns the resin: our engineers have tested and selected the best resins available on the market regarding impermeability, hardness and treadability, and have studied the degree of opacity of a resin to obtain the most optimal degree of opalescence in hiding the points of the LEDs without reducing their brightness too much.

Magnet


The profiles can be equipped with magnetic supports, which allow fast fixing and which can be removed and repositioned several times. Depending on the need for installation, the most suitable supports will be used.

Bending in calender


The aluminum extrusions used for the LEDs have particular shapes, such as openings, grooves and cooling fins. During the bending process an effort is exerted on the cross section which can induce distortions. The curved aluminum profiles also perform an aesthetic function, so the surface quality is essential. Attention to the process and the use of special tools guarantee maximum surface protection. The bending and processing of aluminum takes place in dedicated systems in environments not contaminated by ferrous materials. In most cases, the bending by calendering is the most flexible and efficient method for prototype and small-medium series production. The profile is dragged between the rollers by interpolating a circumference with the desired radius. This is the ideal method for profiles with a complex section and with variable radii, such as those used for LEDs. To estimate this type of operation it is necessary to identify the necessary profile. Based on the necessary radius or diameter measurements, the feasibility is evaluated, as each profile and relative coverage have minimum bending radii and achievable shapes. Depending on the required diameter or shape, it will eventually be necessary to realize the calendered profile in several sections, taking into account the maximum length of the available profiles.
 

Extrusion at 6 meters


The extrusion of aluminum is a mechanical process of plastic deformation which consists in forcing the material, in a pasty state, by compression, to pass through a matrix that reproduces the external shape of the piece to be obtained. At the exit from the matrix the material is cooled. With extrusion, profiles are created without welding with a constant section along their entire length. Extrusion is a high-tech manufacturing process where the attention to detail really makes the difference. The extrusion allows the production of bars with lengths up to 6 meters upon specific request.
 

Resin coating


ADVANTAGES: Resining the profile allows obtaining a product with a high IP degree. The product is made in our office in all its parts, obtaining a customized product that responds optimally to the customer's requests. By varying the type of resin we can have profiles with diffusing resin, or with a high degree of transparency, up to the walkable versions. The realization of the product with the resinated cable inside allows the customer to choose the length necessary to proceed with the installation without making joints on the cable.

PROCESS: Proceed with the careful cleaning of the aluminum profile and subsequent installation of the LED strip. After making the electrical connection, a prolonged operation test is carried out to test the entire electrical part and the gluing of the LED strip to the profile to ensure maximum dissipation. The compound for the resin treatment is then prepared; we start by mixing the various components which are then inserted into a deaerator, which eliminates the inclusions of air from the mixture by means of a high vacuum. The resin is then applied to the profile, positioned on a perfectly leveled solid granite top to have a perfectly linear resin finish. At the end of the catalysing process, the resin bar is further tested for a long time to verify that everything is perfect.

RESULT: The product obtained allows to have a high IP rating, since inside there is no type of air space. The cable entry is also resin-coated inside the bar, thus ensuring a complete seal, even at the ends of the bars.

Galvanic treatment


The galvanic process consists of electrochemical deposition of a thin layer of a metal or an alloy so that the surface properties of the support are modified, both from a technical and an aesthetic point of view. Through galvanic treatments, it is possible to improve corrosion resistance, for example. The treatments we use are carried out by certified companies, according to the UNI-ISO6158 standard. On average, our products are chrome-plated 15 microns thick, with an average hardness of 500hv. The usefulness of galvanic treatments is understandable if one considers that any metal, over time, incurs deterioration caused by various factors, such as wear and the action of atmospheric agents. Therefore we can define the galvanic treatments as aesthetic and protective procedures for metals.
                                                                                                        

Varnishing


Powder coating is a process for coating metal surfaces with an organic film, performed for decorative purposes and / or for protection against corrosion and aggressive agents. The workpieces are covered with a powder coating based on synthetic resins, which adheres to an electrostatic effect, and then passed into an oven where the paint first melts and then polymerizes to give an adherent layer. All our profiles on request, are powder coated with high temperature oven. It is also possible to paint with other RAL colors, at a small additional cost, by requesting a quote and specifying the color.

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