Custom Seam Covers & End Caps for Permanent Eave Lighting Track

Client: Permanent eave lighting installer | Scope: 3D scanning, CAD design, prototyping & production parts

The Problem

This client installs permanent lighting under the eaves of homes. The lights sit inside an aluminum track, and the track goes up in one-meter runs. That leaves two kinds of visible seams on every job: the 90-degree joints at the corners of the house, and the butt joints wherever two straight runs meet. On top of that, the end of each run left raw aluminum exposed.

They wanted covers that would hide all three cleanly, look like they belonged on the track, and go on quickly during an install.

Measuring and Scanning the Track

I started by measuring the track profile with calipers, then 3D scanned both a 90-degree corner joint and the end of a run. Working from the scan meant the covers could follow the real shape of the extrusion, including its channels and edges, instead of a rough approximation.

Here's the scan of the 90-degree corner joint. You can see the track's channels, the mitered seam and even the mounting hole, all captured from the real part.

From the scan data I modeled three parts in CAD: a 90-degree corner cover, a straight transition cover for the joints between runs, and an end cap.

Iteration 1: Full Coverage

The first versions were chunky, full-coverage pieces. The corner cover boxed in the entire joint and the end cap closed off the whole end of the track. They proved the fit and hid every seam, but they were bulky and used a lot of material for what they needed to do.

Slimming It Down

The next rounds went the other direction: slim, clip-on covers that grip the track profile and cover only the seam itself. Much less material, a cleaner look, and they snap on quickly during an install.

I went through several test prints to dial in how tightly they grip the extrusion.

The same approach was used for the straight transitions, where two meter-long runs butt together. A thin band wraps the profile and covers the joint without getting in the way of the light.

The Result

The final set is three low-profile parts: a clip-on 90-degree corner cover, a straight transition cover for the seams between runs, and a slim end cap that closes off the exposed aluminum at the end of a run.

The client now has a consistent, finished look on every run, from corner to corner, and parts they can reorder as they take on more installs.

Have a product or install that needs a custom cover, cap or adapter that nobody makes? Send me the details and photos and let's see what we can build.