February 13, 2020 | Brandon Breznick
As 2020 arrives in full swing, the pattern of implementing high resolution displays into many applications will continue to grow. LCD dominated a good portion of the last decade, with direct-view LED making its impact towards the end. Events like CES 2020 will allow for the public to lay their eyes on displays never seen before with the utmost clearest pictures imaginable. While much of the buzz comes around the screens themselves, there is still a need to position those displays in places that can captivate an audience’s imagination.
All properly placed screens utilize a properly constructed mount. Mounts themselves do not only support weight capacities for screens, but also allows for the best possible positioning for a person’s line of sight. To put a screen in the exact position desired may sometime require a custom mount to be manufactured in order to fit structurally within the intended architecture.
Making a custom mount features many variables that are unseen. There is a great degree of detail involved in creating something custom, nailing each specification down to the precise millimeter. When creating a custom mount, the top three variables that manufacturers require before creating a solution are site conditions, conceptual design, and precision manufacturing.
Site conditions the initial step when deciding how to best make a custom mount. When a person thinks of a mount, usually they associate it with fastening directly to a wall with a load-bearing backing, however with custom applications this is rarely the case. Some free-standing custom mounts may need floor plates and uprights drilled into concrete to support the weight and positioning of a display, while others may require wall anchors drilled into plywood to support displays of great heights. By having boots on the ground, installers can understand what the job site is going to be comprised of and that information can get back to the manufacturer in order to start the design.
After the site is examined, our team has a greater idea of what pallet we have to work with. Getting the exact dimensions of the integrated space along with the many different structural elements around it means that our design engineers can piece together the items needed to create a visual structure. When a design is made, there may be several rounds of revisions and adjustments that need to be made when communicating with both the installers and the end users. Once all parties can come to agreeance on what a structure entails, the final design is 3D modeled and put into visualization software to show a fully scaled arrangement that creates the custom mount.
With a design created, visualized, and agreed upon, the production and manufacturing can begin. Throughout the production line, raw sheet metal is formed to create metal components and brackets of many different sizes. Depending on the size of the components, sheet metal is cut using a high-powered laser to precise dimensions before moving onto a 12-foot press break. The break forms the cut sheets into the basis of what the mounting solution will encompass. The most important part of manufacturing is making sure all brackets and components pair perfectly with the displays that will be going on the custom mount. The last of the custom design includes welding to fuse pieces together and powder coating which gives the custom mount a finish preventing against damages and even against the elements of the weather.
While custom mounting requires a lot of detail, it can bring the biggest visual experience possible by pairing high-resolution displays with ornate architectural design.
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