About Dahlhaus Lighting

Each of our products is individually crafted for you in our workshop, following the tradition of true craftsmanship. We use almost exclusively high-quality cast aluminum components. This material is rustproof, highly durable, and significantly lighter than cast iron.

All individual parts are produced in our in-house foundry from solid cast aluminum. We deliberately avoid inexpensive injection or die casting processes. Instead, we rely on the traditional sand casting method. This technique offers great design flexibility, is ideal for small and medium production runs, and is particularly well suited for custom-made, one-of-a-kind pieces.

In this process—also known as hand molding—a negative mold is created from molding sand. After being filled with molten aluminum, the mold is broken open to remove the finished casting. This individual production method enables us, for example, to cast custom lettering or logos directly into doorbell plates and mailboxes.

The aluminum is poured into the prepared sand molds at a temperature of approximately 750°C (1,380°F), where it cools and solidifies within a short time. Each mold consists of two precisely fitted halves and can only be used once. Metal flasks are used to hold and accurately align the mold halves.

Once the metal has cooled, the sand mold is broken apart and the raw casting is removed. At this stage, the individual cast parts are still connected; any remaining sand and the gating system are carefully removed. Only then does the casting leave the foundry for further precise finishing and refinement.

Every Dahlhaus Light-Fixture, Mailbox and Accessory is now grinded, cleaned and drilled to its exact specifications. By pre-constructing every product in the factory, we make sure that it will fit once it reaches our customers homes.

At last we spray paint all our products with a durable protective finish before giving it the color of your choice. Our custom and hand-applied patinas help to bring out the fine details in every casting. We then install the electrical components and glass panels. The glass is held in place by a traditional ‚permanently elastic‘ putty that provides a strong yet flexible bond. From here you can pick up your order in our factory showroom or it will ship to you around the world.