Producing an IP67-rated flood light requires careful selection of materials and a meticulous assembly process to ensure it is completely protected from dust and can withstand temporary immersion in water up to 1 meter deep for 30 minutes. The IP67 rating is a standard for ingress protection, with the "6" indicating a "dust-tight" enclosure and the "7" signifying protection against water submersion.

Key Components and Materials

Housing: The enclosure is the primary component for achieving the IP67 rating. Die-cast aluminum is a common choice because it's durable, corrosion-resistant, and an excellent heat sink. The design often includes heat dissipation fins.

Seals and Gaskets: To create a dust-tight and waterproof seal, silicone waterproof rings and high-temperature sealants are crucial. These materials must be resistant to extreme temperatures, UV rays, and general aging. 

Lens/Cover: The front of the flood light requires a durable, transparent material. Polycarbonate or plexiglass are good options as they are impact-resistant and can be sealed effectively.

Internal Components:

LEDs: Use high-efficiency LED chips (e.g., from brands like Osram, Philips, or Nichia) that can withstand the heat generated within a sealed enclosure.

Thermal Management: Because the housing is sealed, heat dissipation is critical. Use thermal paste or pads to transfer heat from the LED chips to the aluminum heat sink. The design of the heat sink, including the orientation of its fins, is vital for efficient heat transfer.

Driver: The LED driver must be rated for the operating voltage and designed to handle high-low temperatures. It can be integrated into the fixture or placed in an external, sealed box.

Wiring: Use high-temperature, outdoor-rated wiring and a strong cable waterproof fixed head to prevent moisture from entering along the cable.

Production and Assembly Process

Design: The initial design must account for the IP67 rating from the ground up, including the placement of seals, the shape of the housing for optimal heat dissipation, and the cable entry point.

Housing Fabrication: The housing is typically die-cast from aluminum. All mating surfaces must be precise and clean to allow for a proper seal.

Component Assembly:

Mount the LED modules onto the heat sink using thermal paste to ensure efficient heat transfer.

Solder or connect the wiring to the LED chips and driver.

Apply silicone sealant or place waterproof rings on all seams, including where the lens meets the housing and where the cable enters the fixture. In this step, manufacturers with bulk order may need automatic glue dispensing robot to apply silicone in a fast and uniform manner. GDS automation has mature flood light silicone application experience with diverse machine module. You are free to consult and send sample for testing. It enables flood light manufacturers to get higher product quality and output.

Sealing and Enclosure: Secure the lens to the housing with bolts, ensuring even pressure on the seal. The cable entry point must be tightly sealed with a waterproof gland or fixed head.

Quality Control and Testing: The final product must undergo rigorous testing to ensure it meets the IP67 standard. This includes:

Dust Test: Placing the flood light in a chamber with circulating dust to confirm no particles enter.

Water Immersion Test: Submerging the flood light in water up to 1 meter deep for at least 30 minutes to verify that no water ingress occurs. This is a crucial step to validate the "7" in the IP67 rating.