SMD LED PCB Board Assembly, LED Light Circuit Board Assembly Service
Full Turnkey LED PCB Board Manufacturing and Assembly Services in China
LED PCB assembly has transformed the world of lighting. Nowadays, you will find LED PCBs wherever lighting is required. It is preferred as compared to other lighting technologies. The technology is evolving day by day with the increasing demand for LED Light Circuit Board Assembly.
The LED industry has a significant impact on the demand after introducing a better LED circuit board Assembly. Now, the LED PCB assemblies are more durable, long-lasting, and high-performing. LED lighting is preferred over traditional fluorescent lamps and incandescent lamps.
At first, LED lighting was not that popular because of the higher heat dissipation requirement. Due to high temperatures, the PCB could not last for a long time, and the LEDs were also affected due to high temperatures. But due to metal core PCBs, heat dissipation is not a problem anymore. Metal core PCBs, such as Aluminum and Copper, can efficiently dissipate heat and reduce the temperature of the board. They can dissipate heat without heat sinks. Typically, you will find Aluminum PCBs for LED because of their low cost and excellent performance.
Turnkey LED PCB Board Assembly
LED Strip Lighting PCB Assembly
LED Aluminum Base PCB Assembly
Metal Core PCB
SMD LED PCB Assembly Machine
What is an LED?
LED stands for Light Emitting Diode. A diode is a semiconductor device, but it emits light when current passes through it. Due to its light-emitting feature, it is known as LED. This special device emits light in the visible range so that it can be used for lighting. It can illuminate any place.
Nowadays, LEDs are used in almost every industry and sector. They are used for lighting and indications purposes. The LED industry is at its peak because of its complete applications.
What is an LED PCB Assembly?
A PCB with all the components installed is known as PCB Assembly. If the assembly is for LED lighting, then it is referred to as an LED PCB assembly. In an LED PCB Assembly, there are several LEDs as required and some other components. The assembly is usually made of aluminum to dissipate heat at a faster rate. It is durable and rigid. It can bear wear and tear and work for a long time. There can be any shape of assembly as required by the buyer. Commonly, you will find LED PCB strips, circular and rectangular boards.
An LED PCB assembly service means the fabrication of PCB and the installation of components on it. It is a long process that includes every step. A turnkey PCB assembly service is a service in which everything is the responsibility of the contract manufacturer. From the procurement of components to the LED PCB assembly testing, everything is the manufacturer’s responsibility.
At JHYPCB, we provide full turnkey PCB assembly services. We can also provide quick-turn prototypes PCB assembly service.
Why LEDs and LED PCB Assemblies?
LED has almost eliminated the use of other lighting technologies, and there are many reasons behind it.
LEDs are very compact, and they take a little space. They can be used in a small space where it is difficult to place an incandescent bulb. LEDs can be easily integrated into complex PCBAs because of their small size.
LED PCB assemblies are very compact, and any kind of design can be easily achieved by placing multiple LEDs as desired. There is design flexibility in LED PCB assemblies.
LEDs are long-lasting as compared to fluorescent and incandescent light. They work approximately 25 times longer than other technologies. Therefore, LED is preferred because you don’t need to replace it frequently. Consequently, it saves money. The LED PCB assembly is the reason that makes it long-lasting because it dissipates the heat effectively.
LED lights are more efficient because they do not need to heat up to produce light. They produce light when current passes through them. This is the reason there is a minimum loss of energy in terms of heat. Only 5% of the energy is wasted, and the rest is converted to light. Thus, LEDs consume less energy and can give the same level of light. You can save up to 90% of the energy as compared to other lighting technologies. In short, your energy bill will be greatly reduced if you shift to LED technology.
LED is the most environmentally friendly option that does not harm the environment in any way. Other technologies have mercury and other toxic substances that are dangerous. There is no toxic substance in the manufacturing of the LED PCB Assembly. So, it is safe for the environment.
LEDs can easily work on low voltages. They are better for indoor lighting. They are under less voltage stress. They are much safer, even in the case of any problems.
LED PCB Assemblies can work in every environment, whether it is cold or hot. The assembly is made for versatile applications and can even bear extreme ambient temperatures.
LED Circuit Board Assembly Process
LED PCB Assembly is very similar to other PCB assemblies in the manufacturing process. It involves various steps.
First, the customer places an order after discussing the requirements of the PCB assembly. He provides all the required files and documents, such as Gerber files and BOM. After that, Design for Manufacturability (DFM) is carried out. It is necessary to make the process feasible. At JHYPCB, our experts check the files provided by the buyer and check for any problems. We make sure everything is perfect before starting the process.
Components are placed on the board, so it is necessary to fabricate the PCB in the first step. For the LED PCB Assembly, the PCB is made of Aluminum. Aluminum is an excellent material to offer durability and heat dissipation. In an Aluminum PCB, there are three layers. The first layer of the PCB is the copper layer for electrical connections. The second layer is of a dielectric material, which is responsible for transferring the heat produced by LEDs. The last layer is the Aluminum base layer.
The PCB is fabricated according to the requirements of the buyer.
The components required on the PCB are ordered from different vendors. This step takes time and can take 3-5 days, depending on the components required. The components are ordered according to the BOM list. SMD LEDs, resistors, and other required components are bought.
Solder paste is applied to connect the components with the board. At first, the paste is applied to the bare PCB using a stencil. The stencil helps in applying the paste to the places where it is required. The paste is applied with a wiper. The wiper applies the paste and removes the excess paste. The application of solder paste is for placing and soldering the SMDs.
As the paste on the PCB is applied, it is time to place the components. Components placement is an automated process that is done with a machine. The instructions are given to the machine using a file. The file contains the XY coordinates of the PCB and rotation. It is also known as Pick and Place file. The machine places the components according to the instructions. At this step, the components are only placed at the desired place; they are not soldered.
The PCB is passed through a reflow oven in the next step. Due to heat in the oven, the applied solder melts and forms a connection of the components with the board. After melting, the board is hot, so it is cooled before coming out of the oven.
Reflow soldering is for SMDs. If there are through-hole components, then they are soldered manually. If the PCB is one-sided, then wave soldering can also be helpful and quick. In wave soldering, molten solder is applied at the bottom of the PCB.
There can be many problems with the PCB after soldering. There can be any short circuit, missing joint, or any other problem that needs to be addressed. Inspection is an important step to ensure the performance of the LED PCB assembly. It is done manually in the first step. After that, the AOI (Automatic Optical Inspection) can detect the faults. There are various cameras at different angles to take pictures of the PCB assembly. AOI is a quick process that thoroughly analyses and detects the problems.
X-ray inspection is an advanced inspection method, which is better than AOI. It has the capability to observe connections under the components. The rays are passed through the PCB assembly and create an image after reflection. The images are then analyzed using image processing methods.
Even if everything is up to mark in the final inspection, the results provided by the PCB are not guaranteed. To ensure the proper operation and expected results, the LED PCB assembly goes through a final test. It is tested through various methods, for example, flying probe test, functionality test, and reliability test.
Why are SMD LEDs preferred in LED PCB Assembly?
SMD components are very compact, and they can be easily placed on the board and soldered through reflow soldering. The process is simple and takes less time. SMD LEDs are much smaller than through-hole LEDs. They offer flexibility in designing the LED PCB assembly.
Although SMD LEDs are compact, they provide considerable lumen output, which is the reason they are preferred. Moreover, they consume less energy. These LEDs have three colors (Red, Green, and Blue), so any color can be achieved by the combination.
In SMD LEDs, there are small connectors on both ends of the device. These connectors can be used to join the component to the board.
5050 LED PCB Assembly
5050 LED is a type of SMD LEDs. The size of these LEDs is 50mm x 50mm, which is the reason for their name. It can provide around 1000 lumens per meter. These LEDs contain three to four chips in a single package to offer different colors. If there are three chips, then the SMD can provide three colors: Red, Green, and Blue. Four chips are for Red, Green, Blue, and White. The LEDs have RGB color characteristics to obtain any color through combination.
Due to different colors, these LEDs are preferred for colorful lighting. These are used to make colorful stripes that can be used for decoration and lighting. 5050 LED PCB assembly remains in demand.
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Get the Best LED PCB Assembly Services
JHYPCB proudly offers the best LED PCB Assembly services. We are one of the well-known LED PCB assembly manufacturers in China. Our quality management system is according to international standards and is certified by ISO, RoHS, and UL. We ensure high quality and quick turn LED PCB assembly services. We have a wide range of pre-designed LED PCB assemblies, and you can also order custom assemblies according to your needs. Moreover, we are good at turnkey PCB services. We will take care of everything from the first step to the last. For more information and details, feel free to contact us.