CNC Machining to Cost-Effective Die Casting

When most people began relying on smartphones for photography, Light set out to change what was possible. Their goal was to combine the convenience and portability of a smartphone with the professional image quality of a DSLR camera.

Creating this kind of breakthrough technology demanded precision manufacturing, and only one partner could meet the challenge. Dynacast's advanced die casting capabilities provided the accuracy, scalability, and innovation Light needed to make the concept a reality.

The Challenge: Bringing Professional Photography to Your Pocket

Today, everyone is a photographer. With smartphones in hand, people capture life's moments instantly and share them worldwide. But despite their convenience, smartphones have limitations, especially when it comes to optics, image depth, and sensor performance.

Early prototypes suggested CNC machining as one option, but it quickly proved impractical. Machining the component was five times more expensive than die casting, making it unsuitable for large-scale consumer electronics production.

The innovators at Light realized that while smartphones made photography accessible, the results often lacked the depth, richness, and quality of a DSLR. They envisioned a product that could bridge that gap—a camera with professional performance in the palm of your hand.

Convenience Meets Quality: The Light L16 Camera

Light's engineers developed the Light L16 Camera, an extraordinary device that uses 16 internal camera modules with varying focal lengths. These modules capture multiple images simultaneously, allowing computational software to stitch them together into a high-resolution, DSLR-quality photo, all from a chassis the size of a cell phone.

To make that happen, every millimeter of the L16's lightweight, compact chassis had to be perfect. The internal structure needed to support the intricate arrangement of lenses, sensors, and optics—all while maintaining tight tolerances and a premium consumer aesthetic.

Shedding Light on a Manufacturing Challenge

From the start, Light knew the chassis had to be small, strong, and cost-effective—qualities difficult to achieve simultaneously.

Early prototypes suggested CNC machining as one option, but it quickly proved impractical. Machining the component was five times more expensive than die casting, making it unsuitable for large-scale production.

Having partnered with Dynacast before, Light turned to their team for a better solution.

"Let there be no mistake: it was very challenging on Dynacast's side to make this happen," says Jennifer Hochstatter, VP of Operations at Light. "We were demanding of die casting, and they rose to the challenge—taking a risk on a small, unproven company, and they made it work."

Seeing the Process Through: Dynacast's Die Casting Expertise

The greatest hurdle of the project was creating a die cast part small enough for the L16's compact body, while ensuring it could be reproduced efficiently at scale.

Dynacast's team leveraged decades of expertise in precision die casting, designing a solution that could meet the ultra-tight tolerances and thin wall requirements Light's design demanded.

"This camera really pushes the boundaries of what die casting is capable of," explains Jennifer. "That's why we needed Dynacast's help—to achieve those incredibly tight tolerances and demanding specifications."

In addition to structural precision, the interior and exterior finishes of the camera were critical. The internal cavity required a non-reflective surface to ensure flawless optical performance, while the outer casing needed a premium surface finish that reflected the product's design excellence.

Dynacast applied specialized surface finishing and anodization techniques to deliver both functional and aesthetic results.

"That processing isn't easy to get just right," says Jennifer. "Dynacast could do it—their ability to apply the finish precisely was essential. The aluminum material we used is very unique, and they're one of the only companies in the world capable of this."

Investing in Innovation: A True Partnership

Through close collaboration and technical innovation, Dynacast helped Light move from a concept to a scalable, manufacturable, and visually stunning product."Having Dynacast as part of this project proved they're not just a manufacturer—they're a true partner," Jennifer says. "They believed in the vision and helped make this game-changing camera a reality."

The partnership between Light and Dynacast resulted in a camera that redefined what was possible in portable photography, combining superior optics, computational imaging, and high-precision die casting.

By replacing cost-prohibitive CNC machining with Dynacast's cost-effective die casting process, Light achieved the perfect balance of size, performance, and design quality without compromising on innovation.

Key Takeaways

• Challenge: Create a compact, lightweight camera chassis with precise tolerances.

• Solution: Replace expensive CNC machining with Dynacast's high-precision die casting.

• Result: A production-ready camera with DSLR-level quality at a fraction of the cost.promise on camera size, manufacturing cost, or overall aesthetic design.