Durability, Thermal Performance, and Aging in Outdoor Use

Housing material plays a critical role in protecting internal components and managing heat. Two common choices dominate outdoor solar lighting: die-cast aluminum and plastic housings.

Die-cast aluminum: structural stability and heat dissipation

Aluminum housings provide excellent mechanical strength and thermal conductivity. They help dissipate heat from LEDs and electronics, improving performance stability.

Strengths

          Superior heat management

          High structural rigidity

         Better resistance to UV aging

Considerations

          Higher weight

          Potential corrosion without proper surface treatment

Plastic housings: lightweight and corrosion-resistant

Plastic housings resist corrosion and reduce weight, making installation easier. However, long-term UV exposure and thermal cycling can degrade material properties.

Strengths

          Lightweight

          Corrosion resistance

          Lower material cost

Considerations

          Reduced heat dissipation

          UV aging and brittleness over time

Material choice depends on environment

Harsh climates, high-power systems, and long duty cycles often benefit from aluminum housings, while lower-power or corrosion-prone environments may favor plastic with appropriate design safeguards.

Engineering takeaway

Housing material influences thermal behavior, aging, and mechanical integrity—not just appearance.