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Pexco's Capabilities Shine Wide

A case study glimpse that exemplifies and underscores the Pexco proposition to customers 

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One of the largest indoor lighting OEM’s wanted to take an extremely wide, complex three-piece lens design and develop a single-piece solution that would facilitate installation and maximize performance, dispersing light without creating shadows within the creases of the fixture.



Leverage design engineering, in-house tooling techniques, material blend formulation and consultation, and precision, tight-tolerance manufacturing to satisfy challenging customer and product demands.  


Innovative Thinking:

For over 60 years, Pexco has evolved through a series of small integrations of family owned businesses into a trusted plastic advisor within the Lighting market.  Pexco’s history and reputation direct customers to Pexco’s engineering consultants for guidance on projects, which is how is this project came about.


One of Pexco’s largest customers and largest indoor commercial lighting OEM’s came to Pexco with an project for a 2’X2’ and 2’X4’ recessed lighting fixture.  At the time, the customer was using two sheets and one profile extrusion that inserted together to create a single lens.  This design was not optimal.  The main issues with the three piece design were the amount of assembly time required and the shadows formed when the sheet and profile came together.  Pexco’s customer wanted to create a one piece extruded lens to help eliminate these flaws.  However, Pexco at the time had never extruded more than a 20” lens and this lens would require a width of 22.7” with an extremely thin wall and complex profile geometry.


Maintaining symmetry over a multi-curved, acrylic blend lens with a thin wall and a 22.7” wide profile was quite a challenge. The plastic flow through the die became critical to achieving the complex shape of the profile.  In addition to the profile complexity, an unusually small tolerance for length and squareness was necessary, as well as a specified directional bow along the entire length to prevent sag

To achieve the desired design results, Pexco had to think well beyond normal design practices.  Tooling was critical and had to be modified more than once to achieve optimal performance.  Pexco’s main goal was always to deliver the part to its print specification, and maintain a repeatable process so that year after year, consistent, high quality parts are made for our customer.


Simultaneously, Pexco’s engineering resin experts also worked on perfecting the acrylic blend for the lens, using over four different types of resins to hide the lamp and achieve optimal light transmission.  From design to delivery, Pexco was able to complete this project in 12 weeks and over the last few years has been able to save the company over $250,000 based on the conversion of three parts to one. 


Today, Pexco is one of the only specialty plastic processing manufacturers that can extrude a 23” lens. Pexco’s years of experience processing highly engineered polymers, including acrylics and polycarbonates, has given Pexco a deeper understanding of lighting components and how to create a solution for almost any challenge.


About Pexco:

Based in Atlanta, Georgia with several manufacturing plants across the United States and Mexico, Pexco is a North American leader in the design and fabrication of specialty plastics products.  It provides standard and custom products and components to manufacturers and end-users for a broad range of Industrial market applications, including the Lighting, Fence, Filtration and Traffic Safety sectors.  Pexco meets the requirements of ISO 9001:2015 and other key registrations and/or certifications for its manufacturing operations. Pexco is your trusted advisor for specialty plastic products and solutions.  For more information, visit or contact 770-777-8540.


Pexco’s success in the custom extrusion of top quality, high performance, low stress polysulfone tubing exemplifies confidence in our ability to meet and exceed even the toughest project requirements.


Over the years, Pexco has invested in secondary services such as hole drilling, facing, notching and punching to enhance the form, fit and functionality of the polysulfone end product.