LED Linear Lighting for Swimming Pools – Seamaid

🏷️ Electronics 2024 24 months 🏢 Seamaid

Linear LED pool lighting – Seamaid

An innovative pool spotlight - Made in France!

🏢 Mermaid
🏷️ Sector: Electronics
📅 Year: 2024
24 months
🔢 5 steps

Project Highlights

ClientMermaid
SectorElectronics
Year2024
Duration24 months
Steps5
Process1
Services5
Testimonials💬 1

Manufacturing Processes

⚙️ Plastic injection moulding

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📖 Project history

Project Stakeholders

A strategic collaboration to reshore production.

💡 Alphadif (Seamaid)

Undisputed leader in LED pool lighting. Historically focused on production in China, the company strategically wanted relocate its production to France for its new innovative range.

Factory

French industrial partner, an expert, chosen for its ability to offer a solution Full Service from engineering to the delivery of the finished packaged product.

🤝 The Meeting An introduction orchestrated by a trusted common partner, sealing the beginning of a human and technical industrial venture.


The Challenge

To develop a complete solution from a simple specification document.

«Transforming the idea into an industrialisable, reliable, waterproof, and aesthetically pleasing product, ready for commercialisation.»


Development

A complete course mastered from start to finish.

  1. Specifications document

    In-depth needs analysis and feasibility study to ensure lighting performance and durability.

  2. 🔬 Laboratory Validation

    Rigorous testing of prototypes to validate sealing, thermal dissipation, and optical quality.

  3. 📦 Full Service

    Delivery of a finished product: assembled, decorated, including final packaging ready for distribution.


Industrial Means Deployed

State-of-the-art infrastructure to guarantee quality.

  • 6 Injection moulds Specifically designed for the technical parts of the projector.
  • Assembly line Full line including rigorous assembly and quality control.
  • 💡 Lighting test bench LED intensity and colourimetry check.
  • Waterproofing test bench IP68 guarantee for total and long-lasting immersion.
  • 🔎 Unit traceability Individual monitoring of each product for impeccable quality.

The Result

Thanks to Hybster's expertise, Alphadif now offers an innovative, high-performance, and locally manufactured linear projector.

Produced in France

Project timeline

  1. Step 1 · Engineering

    Mechanical / Plastic Design

    4 months

    • Product redesign after handover by a general engineering office
      • Thickness optimisation
      • Plastic injection process-compatible design
      • Review of screw fastening systems
      • Material selection / review
      • Sealing function optimisation
    • Bill of Materials (BOM) and cost per component optimisation (design to target cost)
  2. Step 2 · Prototyping

    Prototyping and functional testing

    6 Months

    CNC Machining Prototype Development
    First wave of leak testing

     

  3. Step 3 · Industrialisation

    Industrialization

    4 Months

    Injection mould making
    Design and implementation of assembly lines
    Sourcing components

  4. Step 4 · Industrialisation

    Development and testing

    6 months

    • Performing test batches for transformation parameter validation
    • Assembly and debrief
    • Metrology and process/product capabilities
    • Tooling and assembly process development
  5. Step 5 · Assembly

    Production


    Mass production

Project Gallery

6 photographs

⚙️ Manufacturing processes used

1 process

💬 What our client says

The meeting with the Hybster team made this project achievable within market-acceptable timescales.
From a prototype created by a general design firm, Hybster applied the rules of plastic component design, while also sourcing local packaging, instructions, and stickers for the project. Throughout the project, the technicality and traceability of the assembly line evolved to reach the highest level of standards.

— Seamaid - Philippe POMA

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