• Reeves specializes in LED lenses; we have for 20 years.  Consistently extruding lenses is harder than normal extrusion because any impurities, defects or variations are easily seen behind LED lights.  Over the years, we built our culture and processes around being an LED lens supplier as our primary goal, rather than just another capability, or product line.
  • Our long history of making lenses also enables us to provide valuable insight on design for extrudability and fit with aluminum fixtures.  We’ve also blend thousands of formulations of different colors and compounds to hit specific light transmission and diffusion targets.  We know what works and what doesn’t.  We also constantly search for new materials to increase the performance of the lens.
  • Here is a brief overview of our LED lens capabilities:

Overview of Our Compounds

Acrylic

  • Most frequently used in LED lenses due to clarity and performance
  • Types
    • Clear – Used in optical and Fresnel lenses.
    • Frosted – Used to help hide the diodes.  Our frosted materials also have similar light transmission to clear acrylic.  They also have a textured finish.
    • Diffuse – Similar to frosted, but with a smooth texture.  Diffuse can help hide diodes better than frosted, but can significantly decrease light transmission
    • Impact modified – Impact modified acrylic helps make the lens more flexible, which is important when snapping into the aluminum frame.  Impact modified also helps prevent cracking and splintering overtime in outside applications.  Impact modified acrylics are available in clear, frosted and diffuse grades.

Polycarbonate

  • Our polycarbonate is optical grade
  • Polycarbonate is much harder than acrylic, but can yellow over time especially in outside conditions
  • We have several UV and diffusion options we can blend with polycarbonate to help achieve light transmission and hiding power.

Colors

  • We can add color or buy pre-colored material to hit your color targets.
  • We’ve also developed proprietary colors that help improve performance, including:
    • Reeves White:  Gives the lens a nice white glow when the LEDs are on and off.  There’s no premium for this white, we just want you to have a nice lens.
    • Diffuse White:  This helps reduce dark areas on the edge of lenses, or in corners
    • Highly Reflective White:  Typically coextruded on legs, this helps improve light transmission with the added benefit of reducing dark areas on the edge of lenses or in corners

Blending

  • We custom blend colors and compounds to achieve your light transmission and diffusion targets.
  • We custom blend compounds and colors for nearly every job we run.
  • We thoroughly mix the batches in a mixing machine to ensure consistency throughout the batch.
  • We precisely measure compounds and color to create batches of material.  The precision allows us to achieve the same profile performance for each order.

Regrind

  • We don’t use regrind in our lenses.  Many extruders will reuse regrind to help save costs, but regrind introduces impurities into the lens and variability on performance.
  • We recycle about 95% of our waste back into our extrusions because we believe in playing our part in preserving our environment.  We just use it in our other product lines.

Shapes / Profiles

We run several hundred different profiles each year.  In general, we can run:

  • Mono and coextrusion
  • Width: Up to 24 inches
  • Thickness:  0.020 inches to more than 0.250 inches
  • Length:  Typically range from 0.25 inches to 25 feet, though we’ve run longer pieces.
  • Common Shapes / Profiles
    • Fresnel lenses
    • Batwings
    • Tubes
    • Squares
    • Collimators
    • C-Channels
    • Asymmetric flow, such as a thick lens and thin legs
  • Tubes
    • With 50 years of experience, we’ve figured out how to minimize die lines and keep the walls consistent which will help your tube glow without shadows
    • We have in-house tooling to go from 0.50” to 8.00” OD.

Tooling

We’ve made our own tooling for 50 years

  • 50 years of experience (including mistakes) goes into every profile
  • Typical lead time for tooling is 4-6 weeks
  • Tooling pricing also includes first article samples

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