MES Inc. Helps Light Up the Super Bowl

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MES Inc. helped Ephesus Lighting light up U.S. Bank Stadium for Super Bowl LII in Minneapolis.

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MES Inc., a full-service provider of global manufacturing and supply chain services, provided engineering solutions for Ephesus Lighting, a division of Eaton, which enabled the U.S. Bank Stadium to light up for Super Bowl LII in February 2018.

In order to light the stadium properly, Ephesus engineers conceived a high-performance housing requiring extensive ribs for thermal conductivity. During the die-casting process, air pockets can form and get trapped in the layers of the aluminum, creating a condition known as porosity. Porosity was not acceptable in this application as trapped moisture in the porous component causes a build-up of condensation, which can result in an electrical shortage. The component had to have very low porosity, which would be measured by performing leak testing on the finished assembly.

The component also had a combination of cored and machined holes for assembly, and it was large and heavy enough that it had to be cast in a 2,000-ton or larger press.

To meet all of these requirements, MES put into practice several tooling changes to improve the material flow and eliminate porosity concerns. MES conducted Mold Flow analysis to ensure good tooling layout, runner and gate design. Mold Flow software helps companies reduce the tooling tryout times by designing the tooling correctly at the start. MES engineers implemented a host of design changes to improve and add more venting, making it possible for the air to escape faster. They also used a runner system to change the way materials move through the tool. In this case, the material followed pre-cut patterns that allowed it to flow quickly while also maintaining an equal temperature.

For the Ephesus Lighting project, tooling modifications were completed, and a machine process was established to eliminate surface porosity after machining. MES used the Pressure Test Model C20 Sentinel to establish and implement leak test parameters. The company is prepared to perform leak testing in future projects that have similar requirements.

Feedback from Super Bowl LII confirmed that the lighting performance was outstanding. The positive response is a testament to the superior lighting capabilities that Ephesus Lighting designed and developed for the stadium. MES played a small but highly significant part in the process by providing an engineering solution that eliminated any issues related to porosity.

MES provides engineering services, including global manufacturing resources and supply chain management, to a wide range of industries throughout the world. In addition to its headquarters in Lewis Center, Ohio, the company has locations in Mexico, China, India, and Poland.

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Marjorie Clayman