Project Overview

A customer approached BBT with a requirement for a more flexible mounting solution for linear LED lights. The installation locations had different mounting widths, making conventional fixed brackets difficult to use. Developing separate brackets for every installation size would have increased product complexity, installation time, and overall project costs.

Based on the customer’s application requirements, BBT developed a custom metal mounting bracket with adjustable sliding supports on both sides. The design allows installers to reposition the mounting points according to the actual site conditions, providing a more flexible and secure installation solution.

The Customer’s Challenge

The customer needed to install linear LED lights across multiple locations where the spacing between the existing mounting points was not always consistent.

A standard fixed-size bracket created several challenges:

• Different mounting widths required different bracket sizes.

• Existing fixing points could not always be reused.

• On-site modifications increased installation time.

• Improvised mounting methods could affect stability and appearance.

• Managing multiple bracket versions complicated purchasing and inventory.

The customer therefore needed one adaptable structure that could accommodate a wider range of installation conditions.

BBT’s Custom Solution

BBT designed a galvanized steel mounting structure incorporating sliding supports at both ends.

The supports can move horizontally along the crossbars, allowing the installer to adjust the fixing positions before securing the bracket. The linear light is mounted to the central metal plate, creating a stable connection between the luminaire and the building structure.

This adjustable design provides greater flexibility than a conventional fixed bracket and reduces the need to develop separate mounting components for every installation width.

Key Design Features

Adjustable Sliding Supports

The mounting supports on both sides can be repositioned to match different installation widths and existing fixing points.

Flexible On-Site Installation

Installers can adjust the mounting position according to actual site conditions, reducing the need for drilling additional holes or modifying the bracket on site.

Durable Galvanized Steel Structure

The bracket is manufactured from galvanized steel to provide reliable mechanical strength and improved corrosion resistance.

Secure Luminaire Mounting

The central mounting plate supports the linear LED light and helps distribute the load across the complete bracket structure.

Simplified Product Management

One adjustable mounting system can replace several fixed-size bracket versions, helping reduce SKU complexity, inventory pressure, and installation errors.

Customizable Dimensions

The bracket length, mounting range, metal thickness, fixing-hole positions, and luminaire connection structure can be customized according to the customer’s product and installation requirements.

Development Process

BBT worked with the customer to understand the luminaire dimensions, installation environment, required mounting range, and structural requirements.

Our development process included:

1. Reviewing the customer’s installation conditions and dimensional requirements.

2. Evaluating the limitations of a conventional fixed mounting bracket.

3. Developing an adjustable sliding structure.

4. Matching the central mounting plate to the linear light.

5. Producing samples for assembly and installation evaluation.

6. Refining the structure based on testing and customer feedback.

This approach ensured that the final bracket was practical for production as well as convenient for on-site installation.

Project Results

The customized bracket provided the customer with a more versatile mounting solution for linear LED lights.

The final design helped to:

• Accommodate different mounting widths.

• Improve installation flexibility.

• Reduce on-site modification work.

• Increase mounting stability.

• Minimize the number of bracket versions required.

• Simplify purchasing and inventory management.

• Support future linear light models through structural customization.

More Than a Standard Lighting Component

This project demonstrates how BBT helps lighting companies solve practical installation challenges through structural design and supply-chain coordination.

Instead of simply supplying a standard metal bracket, we analyzed the customer’s application and developed an adjustable structure around the actual installation conditions.

As a Lighting Structure Optimization Specialist, BBT supports lighting brands, importers, contractors, and product developers with:

• Custom mounting structures

• Metal stamping and fabrication

• Installation component optimization

• OEM and ODM development

• Prototype and small-batch validation

• Production and supply-chain coordination

Need a Custom Mounting Solution?

If your lighting product requires a special mounting bracket, adjustable installation structure, or customized metal component, BBT can help turn your requirements into a practical and production-ready solution.

Contact BBT to discuss your lighting installation challenge.