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Custom Engineering

When Standard
Products Don't
Fit Your Project.

Standard LED fixtures solve 80% of architectural lighting projects. The other 20% need something different — a modified product, a bespoke mounting solution, or a fixture that doesn't exist yet. That's where TPK's engineering team comes in.

💬 WhatsApp First
Scenario 01
The product exists, but doesn't quite fit
Wrong colour, wrong beam angle, wrong mounting interface — we adapt the standard product to match your project conditions.
Scenario 02
The installation condition is non-standard
Bridge railing, curved facade, glass surface, recessed pocket — we engineer the bracket and fixing system that makes it work.
Scenario 03
The product you need doesn't exist yet
Unique application, specific performance requirement, entirely new form factor — we develop it together from the technical brief.
Three Types of Custom Work

What TPK's Engineering
Team Can Do for Your Project

Every custom request is different. Most fall into one of these three categories — and many projects combine two or three simultaneously.

⚙️
Type 01

Product Adaptation

Modify what already exists

The engineering is done, the product is certified and proven — it just needs to be adjusted to match the specific conditions of your project. Faster and lower cost than developing from scratch.

Housing colour matched to RAL code — any standard RAL, including the architect's specified finish
Beam angle adjusted for the actual mounting distance and surface geometry of the site
Wattage modified for intermediate power levels the standard range doesn't cover
Colour temperature specified for the material and atmosphere of the space — 2700K, 3000K, 4000K or custom
Cable length and connector type matched to the site's distribution system
Ingress protection upgraded for coastal or submerged installation conditions
🔩
Type 02

Bespoke Installation Hardware

Engineer the fixing when the site is non-standard

The fixture itself may be standard — but where it has to go is not. Unusual structures, restricted access points and architecturally sensitive installations often require hardware that doesn't exist in any catalogue.

Bridge handrail and parapet brackets — stainless steel, site-measured, designed for the specific railing profile
Curved surface mounts — for cylindrical columns, arched structures and non-planar facade elements
Glass facade clamp systems — for structural glass and curtain wall applications where drilling is not possible
Recessed installation frames — flush-mount configurations for soffit, ground or in-wall positions
Conduit entry adaptors — for sealed electrical systems and conduit-run installations
Anti-vibration mounts — for bridge decks, elevated walkways and structures subject to dynamic loading
🔬
Type 03

Joint Product Development

Build what doesn't exist yet

Some projects require a fixture that no manufacturer currently makes. If the application is technically feasible and the volume justifies development, TPK's engineering team can work alongside the client from optical concept through to production prototype.

Technical brief review and feasibility assessment — before any commitment
Optical system design — LED array, optic selection, beam distribution modelling
Housing and thermal engineering — form factor, heat management, IP sealing strategy
Driver and control integration — power supply specification, dimming and colour control
Prototype production and photometric testing — with IES measurement data
Certification path planning — ETL, CE or other market requirements from the outset
Custom Engineering in Real Projects

When Standard Wasn't
Good Enough

These projects required something beyond the catalogue. Each one illustrates a different type of custom engineering.

Volgograd Bridge Russia custom cold-climate LED wall washers −40°C engineering TPK
Product Adaptation + Custom Brackets

Volgograd Bridge — Cold Climate & Structural Mounting

Standard wall washers adapted for −40°C cold-start operation. Custom stainless steel brackets engineered for the bridge's specific parapet profile, designed from site drawings without a physical visit.
Turkmenistan National Tower custom RGBW spotlight beam angle star base mounting TPK
Optical Adaptation + Bespoke Mount

Turkmenistan National Tower — Precision Beam & Star-Base Fixture

High-power spotlights adapted with precision narrow-beam optics for the tower's specific throw distance. Custom mounting frames designed for the star-shaped structural base — a geometry with no standard bracket solution.
Jinyun historic waterfront flush mount lens heritage facade custom LED TPK
Optical + Colour Adaptation

Jinyun Historic Waterfront — Heritage-Sensitive Specification

Wall washers adapted with flush-mount anti-glare lenses for a heritage district where standard open-face optics were not acceptable. Colour temperature specified at 2700K to preserve the visual character of the old town streetscape.
Fujiang Bridge Mianyang custom DMX long distance signal transmission engineering TPK
System Engineering

Fujiang Bridge, Mianyang — Long-Distance DMX Signal Architecture

Standard DMX512 signal runs to 300m. This bridge required over 600m of dynamic control without signal degradation. TPK engineered the amplifier network, addressing scheme and cable routing — a system solution, not a product change.
Living World Mall Indonesia three-layer RGBW dynamic facade custom system TPK
Multi-product System Design

Living World Mall, Indonesia — Three-Layer Dynamic Facade System

The facade required three independently controllable lighting layers — outline, wash and accent — each with different fixture types running on a single DMX universe. TPK designed the system architecture and adapted the RGBW products for tropical climate operation.
How It Works

From Brief to
Engineered Solution

Custom engineering work follows a clear sequence. Nothing goes to production before you've seen and approved the proposed solution.

01

Send Your Brief

Describe the project, the installation condition, and the problem that standard products can't solve. Drawings, photos and references all help. The more context you provide, the faster we can respond.

Response within 2–3 working days
02

Engineering Review & Proposal

TPK's engineering team reviews feasibility, identifies the approach — adaptation, bespoke hardware, or new development — and prepares a technical proposal with timeline and indicative cost. No charge for this stage.

Including IES simulation if applicable
03

Sample & Approval

A pre-production sample or prototype is produced for your review before full production begins. For optical adaptations, IES photometric data is provided. For hardware, a physical fit test on site or from a dimensional drawing.

Nothing goes to production without your sign-off
04

Production & Delivery

Full production with QC inspection. Complete documentation — test reports, certificates, IES files, installation guidance — shipped with the product. Post-installation support available.

5-year standard warranty
Is Custom Engineering Right for You?

Good Fit —
Come Talk to Us

✅
You have a specific installation constraint
A structural condition, an architectural requirement, or a mounting position that standard brackets can't address
✅
You need a performance spec the catalogue doesn't cover
A beam angle between standard options, an intermediate wattage, a colour temperature not in the range
✅
You've used standard products before and they fell short
You know what went wrong on the last project — and you want to solve it properly this time
✅
You have an idea for a new product
A concept that meets a recurring need in your market — and you're looking for a manufacturing partner to develop it
Probably Not a Custom Job

Try Standard Products
First

↗️
You haven't checked the standard range yet
TPK's wall washer series covers 18W–150W with interchangeable 15°/30°/45°/60° beam angles and RGBW options — most facade and bridge projects can be solved without any custom work.
Browse standard products →
↗️
You need a project system recommendation
If you're not sure which standard products suit your application, Solutions pages cover the engineering approach for each scenario.
View application solutions →
Common Questions

Custom Engineering FAQ

Housing colour (any RAL code), beam angle, wattage, colour temperature, cable length, connector type, and ingress protection level. Most adaptations don't affect ETL or CE certification — our engineering team advises case by case before you commit to anything.
Yes — if the application is technically feasible and the project volume justifies development. Joint development starts with a no-obligation feasibility discussion. We cover optical design, housing engineering, driver integration, prototype production and the certification path from the outset.
As much context as you can provide: project type, installation condition, the specific problem the standard product can't solve, drawings or photos if available, and any performance requirements (illuminance target, beam angle, colour). There's no form to fill in — just describe the situation and our engineering team takes it from there.
No fixed minimum — it depends on the type of work. Simple adaptations (colour, beam angle) are practical from around 50–100 units. Custom brackets can be done in smaller quantities. New product development requires a volume discussion as part of the feasibility review. Tell us the project first — we'll tell you if it's viable.
Feasibility review and proposal: 2–5 working days. Simple adaptations (colour, beam angle): 25–40 working days including sample. Bespoke bracket design and fabrication: 30–50 working days. New product development: discussed case by case — timelines depend on complexity of the optical and mechanical engineering.