Abstract: A housing assembly for a recessed lighting system includes a housing with integrally formed cable routing features, mounting features, and alignment features. The integration of multiple features into the housing is enabled by forming the housing from a polymer using an injection molding process instead of sheet metal. For a new construction installation, the housing includes integrally formed bar hanger holders to support and guide bar hangers for installation onto two or more support structures, nail-in features for installation onto a single support structure, and one or more alignment features to position the housing against the single support structure when the nail-in features are used for installation. For a remodel installation, the housing includes a flange to abut a bottom surface of a ceiling and one or more spring clips mounted to the housing to abut a top surface of the ceiling.

Abstract: A housing assembly for a recessed lighting system includes a housing with integrally formed cable routing features, mounting features, and alignment features. The integration of multiple features into the housing is enabled by forming the housing from a polymer using an injection molding process instead of sheet metal. For a new construction installation, the housing includes integrally formed bar hanger holders to support and guide bar hangers for installation onto two or more support structures, nail-in features for installation onto a single support structure, and one or more alignment features to position the housing against the single support structure when the nail-in features are used for installation. For a remodel installation, the housing includes a flange to abut a bottom surface of a ceiling and one or more spring clips mounted to the housing to abut a top surface of the ceiling.

Abstract: An LED downlighting apparatus includes a housing with a sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED downlighting apparatus is installed in an opening of the ceiling. A depth of the sidewall is less than one inch and a thickness of at least a portion of the sidewall is less than three millimeters. An LED board and a lens are coupled to the housing. The lens is disposed with respect to the LED board such that the lens is illuminated from a back side. One or more mechanical couplers snap fit the apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snap fit to the junction box through the opening of the ceiling, the housing appears to be surface mounted to the ceiling.

Abstract: A housing assembly for a recessed lighting system includes a housing with integrally formed cable routing features, mounting features, and alignment features. The integration of multiple features into the housing is enabled by forming the housing from a polymer using an injection molding process instead of sheet metal. For a new construction installation, the housing includes integrally formed bar hanger holders to support and guide bar hangers for installation onto two or more support structures, nail-in features for installation onto a single support structure, and one or more alignment features to position the housing against the single support structure when the nail-in features are used for installation. For a remodel installation, the housing includes a flange to abut a bottom surface of a ceiling and one or more spring clips mounted to the housing to abut a top surface of the ceiling.

Abstract: A lettering kit including a plurality of character members corresponding to every letter of the alphabet, each character member comprises a hinge portion between a first portion and a second portion, wherein the hinge portion allows the first portion to move between a first open position and a second closed position.

Abstract: A densified, high-strength metallic component is manufactured by: binder jet additive manufacture (BJAM) printing a powder blend to form a printed part; and super solidus sintering the printed part to form the metallic component, which may then be heat treated. The powder blend comprises a blend of water atomized base iron powder and a high-carbon master ferroalloy powder. The high-carbon ferroalloy powder introduces high concentrations of carbon into a powder blend that is readily BJAM printable.

Abstract: A housing assembly for a recessed lighting system includes a housing with integrally formed cable routing features, mounting features, and alignment features. The integration of multiple features into the housing is enabled by forming the housing from a polymer using an injection molding process instead of sheet metal. For a new construction installation, the housing includes integrally formed bar hanger holders to support and guide bar hangers for installation onto two or more support structures, nail-in features for installation onto a single support structure, and one or more alignment features to position the housing against the single support structure when the nail-in features are used for installation. For a remodel installation, the housing includes a flange to abut a bottom surface of a ceiling and one or more spring clips mounted to the housing to abut a top surface of the ceiling.

Abstract: An LED downlighting apparatus includes a housing with a sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED downlighting apparatus is installed in an opening of the ceiling. A depth of the sidewall is less than one inch and a thickness of at least a portion of the sidewall is less than three millimeters. An LED board and a lens are coupled to the housing. The lens is disposed with respect to the LED board such that the lens is illuminated from a back side. One or more mechanical couplers snap fit the apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snap fit to the junction box through the opening of the ceiling, the housing appears to be surface mounted to the ceiling.

Abstract: A housing assembly for a recessed lighting system includes a housing with integrally formed cable routing features, mounting features, and alignment features. The integration of multiple features into the housing is enabled by forming the housing from a polymer using an injection molding process instead of sheet metal. For a new construction installation, the housing includes integrally formed bar hanger holders to support and guide bar hangers for installation onto two or more support structures, nail-in features for installation onto a single support structure, and one or more alignment features to position the housing against the single support structure when the nail-in features are used for installation. For a remodel installation, the housing includes a flange to abut a bottom surface of a ceiling and one or more spring clips mounted to the housing to abut a top surface of the ceiling.

Abstract: An LED downlighting apparatus includes a housing with a sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED downlighting apparatus is installed in an opening of the ceiling. A depth of the sidewall is less than one inch and a thickness of at least a portion of the sidewall is less than three millimeters. An LED board and a lens are coupled to the housing. The lens is disposed with respect to the LED board such that the lens is illuminated from a back side. One or more mechanical couplers snap fit the apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snap fit to the junction box through the opening of the ceiling, the housing appears to be surface mounted to the ceiling.

Abstract: An LED lighting apparatus comprises a housing having at least one sidewall, an LED board, a lens having a back side facing the LED board and a front side opposite to the back side, and a driver module cover. The lens is disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens. An adapter bracket is employed to couple the LED lighting apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snapped into the junction box, the driver module cover is at least partially disposed in the junction box.

Abstract: An LED lighting apparatus comprises a housing having at least one sidewall, an LED board, a lens having a back side facing the LED board and a front side opposite to the back side, and a driver module cover. The lens is disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens. An adapter bracket is employed to couple the LED lighting apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snapped into the junction box, the driver module cover is at least partially disposed in the junction box.

Abstract: An LED downlighting apparatus includes a housing with a sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED downlighting apparatus is installed in an opening of the ceiling. A depth of the sidewall is less than one inch and a thickness of at least a portion of the sidewall is less than three millimeters. An LED board and a lens are coupled to the housing. The lens is disposed with respect to the LED board such that the lens is illuminated from a back side. One or more mechanical couplers snap fit the apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snap fit to the junction box through the opening of the ceiling, the housing appears to be surface mounted to the ceiling.

Abstract: A thin profile surface mount LED lighting apparatus includes a housing, an LED board including multiple LEDs, and a lens. The lens has a back side facing the LED board and a front side that provides a downward facing surface when the LED lighting apparatus is installed in an opening of a ceiling. The lens is disposed with respect to the LED board such that the LEDs illuminate the back side of the lens. A first spacing of the LEDs causes resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus. In one example, a thin front edge of a sidewall of the housing, forming a perimeter around the lens, is flush with the lens and is appreciably thin (e.g., a thickness of less than three millimeters), and a depth of the sidewall housing is less than one inch.

Abstract: A thin profile surface mount LED lighting apparatus includes a housing, an LED board including multiple LEDs, and a lens. The lens has a back side facing the LED board and a front side that provides a downward facing surface when the LED lighting apparatus is installed in an opening of a ceiling. The lens is disposed with respect to the LED board such that the LEDs illuminate the back side of the lens. A first spacing of the LEDs causes resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus. In one example, a thin front edge of a sidewall of the housing, forming a perimeter around the lens, is flush with the lens and is appreciably thin (e.g., a thickness of less than three millimeters), and a depth of the sidewall housing is less than one inch.

Abstract: A thin profile surface mount LED lighting apparatus includes a housing, an LED board including multiple uniformly distributed LEDs, and a lens. The lens has a back side facing the LED board and a front side that provides a downward facing surface when the LED lighting apparatus is installed in an opening of a ceiling. The lens is disposed with respect to the LED board such that the LEDs illuminate the back side of the lens. A first spacing of the LEDs causes resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus. In one example, a thin front edge of a sidewall of the housing, forming a perimeter around the lens, is flush with the lens and is appreciably thin (e.g., a thickness of less than three millimeters), and a depth of the sidewall housing is less than one inch.

Abstract: A densified, high-strength metallic component is manufactured by: binder jet additive manufacture (BJAM) printing a powder blend to form a printed part; and super solidus sintering the printed part to form the metallic component, which may then be heat treated. The powder blend comprises a blend of water atomized base iron powder and a high-carbon master ferroalloy powder. The high-carbon ferroalloy powder introduces high concentrations of carbon into a powder blend that is readily BJAM printable.

Abstract: A thin profile surface mount LED lighting apparatus includes a housing, an LED board including multiple uniformly distributed LEDs, and a lens. The lens has a back side facing the LED board and a front side that provides a downward facing surface when the LED lighting apparatus is installed in an opening of a ceiling. The lens is disposed with respect to the LED board such that the LEDs illuminate the back side of the lens. A first spacing of the LEDs causes resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus. In one example, a thin front edge of a sidewall of the housing, forming a perimeter around the lens, is flush with the lens and is appreciably thin (e.g., a thickness of less than three millimeters), and a depth of the sidewall housing is less than one inch.