High Bay LED Light

Modular Adaptability

Vision

Big Ass Fans’ vision for a next generation high-bay LED light was to build on a modular platform providing flexibility for installation needs, while maximizing power and energy efficiency.

The core component of this system is the LED bar, this assembly includes the LED board, optical lens, and a robust extruded-aluminum housing designed to dissipate heat generated by the extreme-power LEDs. These bars can be configured in multiple quantities and orientations, with different lenses added to control the angle and dispersion of the light. Additionally, BAF lighting engineers built in the architecture to make product versions ranging from 24,000 lumens to 72,000 lumens. The result is a modular system that adapts to many lighting scenarios and requirements.

Design Challenge

The unique challenge of designing such a system was to consider the extreme power and resulting cooling needs of the LED lights while creating a distinctive industry-leading product worthy of the Big Ass brand. Zukun was tasked with designing a high bay light that still reads as a recognizable Big Ass product even when powered-on, blindingly bright, and mounted 30’ overhead.

Result

Most existing high bay LED lights are either large white rectangles or circular in shape, and both are nearly impossible to distinguish when in-use. Zukun’s final design honored the function of the lights while creating a distinct silhouette from the ground with the lights appearing as two bars floating along either side of a black chassis. Air-gaps between the LED bars and the chassis contribute to the floating aesthetic while providing additional airflow for cooling and the hand clearance needed for ergonomic LED rotation adjustment. The chassis is a simple-but-tough metal structure that holds the LED drivers and other features such as optional occupancy sensors. Yellow end caps on the light bars provide an opportunity to carry this distinctive brand color into the product in a purposeful way. When viewed close-up, the design language is utilitarian with subtle rugged detailing to reinforce the inherent durability of the product.

The final family offering features one or two LED bar options with the ability to rotate them downward for direct lighting, up for ambient lighting, or any position in between. The modular nature of these products allows them to share many components, and the design language builds upon this with a common aesthetic philosophy between the two.