Quality LED PCB Assembly & Manufacturing Services

MOKOLight can design, manufacture, and assembly LED PCB according to your requirements. We have rich experience on producing led pcb for high quality lights, hangē ko ʻení, PCB with UV395nm led chip assembly, PCB with Osram 3535 led chip, and other led chip with lens. We always use high qualtiy Aluminum pcb, led chips and lead-free solder paste.
With strict quality control system, we test every batch led chips by integrating sphere optical tester before production, visual inspection is through whole production, we must do 100% tests before packing. Please send us your Gerber file and BOM list,or let us know your requirement derectly,we will offer good solution for you.

High Quality LED PCB Manufacturing

LED PCB assembly is the process of soldering or mounting a Light-emitting diode to a printed circuit board featuring a chip that produces light when electricity is connected. For LED PCB board, LED PCB board manufacturers use a ceramic base and a thermal heat sink to bond the chip with the LED circuit board. The most preferred base is Aluminum since it has the ability to resist heat.

TATAKI ʻa pb. fakatahaʻanga 1

Board thickness:1.6MM
Layer count:1layer
Copper thickness:2OZ
Thermal conductivity:1.0 W/m.K
Solder mark: Hinehina (high quality, Exposure)
Silkscreen: Black
Surface Finish: HASL

TATAKI ʻa pb. fakatahaʻanga 2

PCB material: Al 5052 MCPCB
Board thickness:1.2MM
Layer count:1layer
Copper thickness:1OZ
Thermal conductivity:1.0 W/m.K
Solder mark: Hinehina
Silkscreen: Black
Surface Finish: HASL

TATAKI ʻa pb. fakatahaʻanga 3

Board thickness:1.6MM
Layer count:1layer
Copper thickness:2OZ
thermal conductivity:2W/m.K
Solder mark: black
Silkscreen: hinehina
Surface Finish:HASL lead-free

TATAKI ʻa pb. fakatahaʻanga 4

Copper-Aluminum composite PCB Let’s introduce a good PCB for you, the Copper-Aluminum composite PCB is widely used to LED Grow Light, high-power power supply.

Performance Table of Different Aluminum Alloys

Performance

Units

1100

3003

5052

6061

Density

g/cm³

2.71

2.730

2.680

2.700

Melting Point Range

°C

643 - 657.2

260 ke 510

607

585

CTE

Um/m. k

23.6 µm/m-°C

23.2 µm/m-°C

23.8 µm/m-°C

23.6 µm/m-°C

Specific Heat Capacity

J/kg-k

904

893

880

897

Thermal Conductivity

W/m. k

222

162

138

151-202

Electric Conductivity

%IACS

59

50

35

47

Resistivity

n Ω. m

30

34

49.3-49.9

32.5–39.2

Rigidity

HB

23

28

61

95

Elongation

(1.6MM)%

25

12

What kind of LED PCB can we make?

1

Layer

1-2layers

2

Board thickness

0.6-3.0MM

3

Copper thickness

0.5-3OZ

4

Thermal Conductivity

1-3W/M.K

5

Max. Finished Board Size

400*1450MM

6

Min. Drilled Hole Size

0.25MM

7

Min. Line Width

0.075MM(3mil)

8

Min. Line Spacing

0.075MM(3mil)

9

Surface Finish

HASL lead free, ENIG, OSP

10

Solder Mask Color

Black / White/ Green / Lanu puluú / Yellow / Kulokula

11

Hole Tolerance

PTH: ±0.075, NTPH: ±0.05

LED PCB Assembly Process

LED PCB Assembly process

High Quality led chip Partner

Osram
Nichia
Seoul
Gree
LG
Edison
Lumileds
Samsung
TT Electronics

What is LED PCB?

Dated back in the 1930s, the first Printed Circuit Board (PCB) was developed by Paul Eisler, an Australian Inventor. This is the same design we see in electronic devices like radios and computers today. He made it specifically to operate a radio system using Charles Ducas’ design-circuit design. Since then, the application and features of PCBs have evolved at a formidable rate making it the next basic ingredient in technology advancement. In Lighting Technology, printed circuit boards have been embedded in Light Emitting Diodes (LEDs) to make them more efficient and dependable. With the help of PCBs, they’re able to produce enough light without emitting excess heat. This makes the LEDs safer and the preferred option for daily use.

In this ultimate guide, you’ll learn about the fruitful relationship between LEDs and PCBs and how it happens. Read on for an inside look at LED PCB Assembly.

Types of LED PCB

There are different LED PCB types. They include;

1. LED Aluminum PCB

Aluminum PCB for LED has good conductivity, and it also portrays excellent heat dissipation abilities. Since LEDs emit a lot of heat, they need reliable heat dissipation to exceed their componentslives by saving them from heat damage. This is why most LED PCB manufacturing companies prefer Aluminum as their ceramic base for their LED light PCB board.

2. LED Strip

They are divided into two types:

1) Flexible LED light strip
It uses FPC as its PCB and utilizes the patch LED to assemble. This makes the final product thick to save space. It’s easy to bend, fold or extend.

2)Rigid LED light strip
It’s made of a rigid PCB. You can assemble by directly connecting to the LED or use patch.

3. Light Emitting Diode display PCB board

It has many LED module panels which are small in size. It’s a flat panel display. Mostly used to display images, videos, texts, video signals, and other info devices.

What Is Aluminum PCB?

This a type of printed circuit board whose base material has an aluminum core combined with a standard FR4. The Aluminum PCB has a thermal clad layer that vanishes heat efficiently to cool components, boost overall performance, and extend the product’s life.

Types of Aluminum Used in the LED PCB Assembly

There are different kinds of Aluminum utilized in the LED PCB assembly services. They include Hybrid aluminum, Flexible Aluminum, and multi-layer Aluminum.

  1. Hybrid Aluminum

Aluminum is combined with a non-thermal material called FR4 (Flame Retardant 4) to make the LED PCB board rigid. This type of Aluminum has better dissipation, and it’s cheaper compared to thermal conductive materials.

  1. Flexible Aluminum

This type of Aluminum consists of polyimide resins and ceramic fillers. This increases its insulation and flexibility. It can bend, extend and fit in different LED PCB board designs.

  1. Multi-layer Aluminum

These types of Aluminum are relevant in complex PCBs-where there’s a need for effective thermal conductivity and high heat transfer. LED light PCBs use less power, and therefore, multi-layer Aluminum is quite applicable. They work reliably and last longer since they lack mercury.

List the Benefits of Aluminum for LED PCB

Aluminum is a renowned ingredient in making highly effective, tuʻuloa fuoloa, and reliable LED PCBs. This is because it has many ideal features for LED light applications. Here are some of the main benefits Aluminum offers for LED PCBs:

  1. It’s affordable

It’s readily available and easy to refine hence reduces its production cost compared to other metals. When used for PCBs, it eliminates the need for other heat transfer methods like a heat sink, thus saving on the overall cost.

  1. Environmentally friendly

It’s recyclable and also non-toxic. When you’ve drained their usefulness, they are easy to dispose of without affecting the environment.

  1. Reduces the weight of the PCB board

It’s lightweight, making it easier to ship and handle. What is more, they are highly efficient, making them ideal for different types of machinery like vehicles and computers.

  1. Durable

Aluminum-made PCBs are more impervious to damage during manufacturing and application. This makes them better than fiberglass or other materials.

  1. Effective heat dissipation

High temperatures don’t affect Aluminum, and therefore, it dissipates heat better than other materials.

How Many Layers Does an Aluminum PCB Have?

Aluminum-made printed circuit boards consist of 3 layers. They are:

  1. Base layer

It’s made up of an aluminum alloy and the part the rest of the PCB components sits on.

  1. Thermal insulation layer

It has a ceramic polymer that helps protect the LED PCB board from mechanical and heat damage. This is the layer that absorbs heat and sends it to the base layer (Aluminum) for dissipation.

  1. Circuit layer

It consists of the copper circuits that are placed as per the LED light circuit board design.

List the Application of LED PCB Assembly

LED PCB Assembly has gained steam in different sectors and is currently applied in computer assembly, automotive assembly, telecommunications, among many others. See below common applications of this technique.

  1. Telecommunications

In telecommunications, products such as LED indicators and displays need PCBs made using Aluminum for high durability, ala falalaʻanga, and effective heat dissipation.

  1. Automotive Industry

Industries manufacturing or assembling cars and other automotive need Aluminum LED PCB assembly to make reliable, durable, and damage-resistant brake lights, indicators, and headlights.

  1. Computer assembling/manufacturing industry

The CPUs and power units in computers are sensitive to heat and can succumb to damage if there lacks an effective heat dissipator. That’s why LED PCB becomes ideal due to its ability to transfer and emit heat efficiently.

  1. Medical Equipment manufacturing/assembling industry

Medical equipment, surgical equipment, hospital lighting, and other lighting tools use LED lights that are highly powered. Ko ia, they need a custom LED PCB that can transfer and dissipate heat efficiently to increase durability and functionality.

Benefits of LED PCB

There are many benefits associated with LED PCB circuit design hence the many applications in multiple industries. Here are some:

  • They are lightweight, making them easy to ship and handle (easy to integrate into complex interface assemblies)
  • They save power/reduce energy consumption. LED lights use at least 75% less than other types of lightings.
  • They are durable. Their lifespan is between 20000 ke 25000 hours· thermal expansion
  • They are efficient in heat dissipation. This is because they use Aluminum in their base layer.
  • They can channel/transfer excessive heat efficiently to the aluminum layer for dissipation.
  • They are moisture and dust-resistant.
  • They are readily available in a variety of sizes, mālohi, and colors. You can easily find one from LED PCB supplier near you.
  • They are friendly to the environmentally and non-toxic because they lack mercury.

Factors to Consider When Developing A BOM For LED PCB Assembly

BOM, abbreviated as Bill of Materials, is the comprehensive inventory or crucial data list of the materials, parts or components, assemblies, subassemblies alongside their quantities required to manufacture a prototype/product. In this case, we’ll discuss what to consider when coming up with the Bill of Materials for LED PCB production.

  1. Choose readily available materials that won’t take a lot of time while looking for them.
  2. Go for durable components. This will help lower the repair and replacement cost.
  3. Mount all components on the same PCB layer to reduce the cost of manufacturing.
  4. The BOM should comprise a footprint, description for each part, comments, and designator for each part.

LED PCB Assembly component mounting technique

There are three methods of placing/mounting components on a LEDD printed circuit board. They are the Through-hole Mounting method, Surface Mount method, and Chip-on-Board (TUPU). In this guide, we will discuss Through-hole and Surface mount only because they are the main ones.

  1. Through-hole Mounting Assembly Technique

Manufacturers have used this technique since the 1940s during the introduction of second-generation computers. It replaced the point-to-point construction. During the 1950s, tracks were only printed on one side of the board, but later drills were introduced to make holes. Components were then inserted through the PCB and fused. Later developments led to tracks printed on both sides as well as the inner layers of the printed board. Now, technologies like plated-through holes have made it possible for components to be connected to tracks in the inner layer of PCBs. There are two kinds of components used in the through-hole mounting technique. They Radial (where leads are put on both sides of the component) and Axial (where leads are put on one side of the component).

  1. Surface Mount Assembly Technique

It was initially known as the Planar Mounting technique. This technique came after through-hole mounting and was introduced in the early 1960s but widely utilized in the 1980s. Components used in this technique have leads below or around packages called SMDs (Surface Mount Packages). In this tech, there’s no need to make holes through the printed board to tracks and components since they will directly contact each other on one side of the PCB. This Assembly technology is widely used by manufacturers today to create masterpieces like the SMD LED PCB board design.

Advantages and disadvantages of through-hole, surface mount, and COB in a table

Each PCB Assembly mounting technique has its pros and cons. See table below.

Type of LED PCB Assembly Technique

Advantages

Disadvantages

1. Through-hole

· Easy to interchange components

· Components suitable for prototyping

· Power saver-Power is consumed efficiently and at low amounts due to the cohesiveness between PCB and components

· Low risks of damage. Has high ability to withdraw stress (excess heat and mechanical damages)

· Costly due to drilling

· Takes a lot of time to solder leads through the drilled holes

· Unreliable due to weak solder joints

2. Surface Mount

· Supports placements of components on both sides of a printed circuit board.

· Using of Pick and Place machine reduces production time.

· Small devices can be assembled

· Has excellent thermal properties

· Automated Assemblies are possible. Favorable for large-scale production.

· Most components cannot support high-power applications.

· components can’t be prototyped

· Components can’t be tested for small circuits.

3. TUPU

· Reduced space requirements

· Quicker to market

· Reduced cost

· Best shielding against reverse-engineering.

· Highly reliable since it offers better heat distribution and has few solder joints

· Light efficiency decreases with the largeness of the chip.

· It offers a limited number of colors.

How Can You Decide Which PCB Assembly technology Is Suitable for You?

The two main types of LED PCB assembly mounting techniques (Through-hole and Surface mount) have their pros and cons. Each is suitable for different products depending on how you’d like your final product to look like, the money you’re willing to spend, the function, fakaʻauha ʻo e malohi, and most importantly, its lifespan.

Hangē ko ʻení, Surface mount PCB assembly is quite a cheap and the quickest way to assemble an LED PCB. ʻI he tafaʻaki ʻe taha, Through-hole is quite old and costly yet reliable and durable as well. Ko ia, whichever technique you choose depends on the outcomes you want.

LED PCB Assembly Specifications

When using LED PCB Assembly, follow these specifics.

Number of Layers

PCB layers are either made of aluminum alloy or magnesium. Aluminum-made Printed circuit boards are the best due to the excellent damage-resistant properties Aluminum has.

Types of Layers

There are 3 main types of layers in an LED PCB. Ko e Base layer is Aluminum made and is used to receive, transfer and dissipate heat. The second layer consists of a ceramic polymer. It passes heat to the base layer. It’s known as the Thermal insulation layer. The top layer, called Circuit Layer, is made up of copper, and it’s where the components are placed.

Board Type

There are two main types of boards: Panel and Single. Single boards have 2 layers and are made up of normal FR-4. A panel board consists of single or multiple printed boards which can be connected or not.

The Number of Flexible PCBs

How fast do you want your device to function? The answer to that question will help determine the number of flexible PBCs you want and how many layers each should have. These PCBs have either one or more layers. More layers mean more speed.

Fua

Manufacturing cost will be determined by the dimensions you choose for your PCB. When choosing these dimensions, ensure that the area to be covered is relatively smaller than the PCB size. You choose the right type of closure, pea fakaʻosi, ensure you maintain a tolerance value to accommodate changes that might occur during manufacturing.

Base Material

Commonly used materials are FR-4(suitable for low thermal devices), the Metal-core (made up of Aluminum and covered with coper-best for high thermal devices), and epoxy-FR-4 though it’s not a good heat conductor making it less durable.

Minimum Spacing

The ideal spacing between components on a PCB should be equal to the height of each component. With this type of spacing, it’ll be easier to solder joints on the board and repair the components in case of damage.

Hole Size

Consider the ratio of hole diameter to the board thickness when manufacturing LED printed circuit boards.

Solder Mask

Its work is to improve PCB reliability and performance. It covers the coper with a resin coating. It resists temperature, solder, humidity, and also insulation. It comes in different colors like green, engeenga, black, etc. depending on the owner’s/manufacture’s choice.

Silkscreen

Used mainly for identification. It shows switch settings, device logo, test points, and component identifiers. Comes in either back or white.

Gold Fingers

These are finger-like structures at the edge of a printed circuit board that serve the purpose of connectors—usually used at places most prone to wear and tear, i.e., keypads.

Stiffeners

Used to support some components of a flexible printed circuit board. They are typically made of FR-4 and comes with different thicknesses ranging from 0.008 inches to 0.59 inches. More thickness means more support.

Surface Finish

They include hot soldier air leveling, immersion in tin surface finish, lead-free hot air solder leveling, immersion silver surface finish, and Electro-less nickel immersion gold surface finish.

LED PCB Assembly Process

As MOKOLight company, we always look to manufacture the best LED PCB. Ko ia, during our assembly process, we;

  1. make sure to define the functions of the PCB,
  2. follow the right requirements needed while choosing the components,
  3. come up with the right BOM,
  4. proceed to the manufacturing stage.

Methods of LED PCB Assembly

There are 2 main methods involved in LED PCB Assembly:
1. Hand Assembly
2.Automated Assembly
  1. Hand Assembly

Involves an expert who mounts different components on the surface of an LED printed board using specialized equipment.

  1. Automated Assembly

Pick, and Place equipment/machines are utilized in this method. Meimei ko e Angamahení, a precise nozzle is combined with a vacuum pressure to do the job. Commonly used for surface mount technique.

Challenges and Solution of LED PCB Assembly Process

Like any other manufacturing process, LED PCB Assembly faces challenges that our experts have identified and provided solutions in this guide. Head over to learn more.

7 Ways to Avoid LED PCB Assembly Setbacks

How to Avoid LED Assembly Setbacks
1. Circuit Scratch
This occurs when you have high-density pads, mainly on the LED side. Reducing the line pitch is the best way to circumvent this issue since it optimizes the angle between the line and the pad.
2. Pad Outline
When aligning pads in a matrix, it is quite likely to have high omission ratios. The trick is to stick to procedural control to limit these errors.
3. Degrading Functions
This occurs when an entire row of LEDs in the matrix fails. The Best way to solve this is by either destroying the affected components or removing the solder mask oil.
4. Solder Mask Oil Peeling
This always occurs from exposure to energy. It can be solved through secondary exposure (which could impact the capacity of solder mask consignment).
5. Unconformity in Solder Mask Oil Color
Strict production conditions and excessive elements play a huge role in this. It can be avoided by picking the best control parameters and techniques.
6. Board Angle Defects
It arises from having a board with fragile side angles or has a high thickness. Correcting this issue is as simple as adding a base plate, which serves as a protective measure.
7. Warpage
This occurs when the board has excessive high-density pads, with the driver side having large copper blocks. The trick is to focus on implementing flatness by reducing the warpage to under 0.5%

The Core Construction of LED PCB

The setup, design, and materials the manufacturer uses for your boards all depend on the intended application. One part that could make or break your LED project is the core of the circuit boards. The boards can be made from a wide variety of cores, including:

  • Falanise-4:as one of the most commonly used PCB board materials, FR-4 consists of epoxy and glass. While it is fire retardant, it isn’t efficient at heat transfer.
  • Metal-core:this type of PCB consists of aluminum alloys that are laminated with copper. These PCBs are invaluable in applications that involve thermal conductivity, heat transfer, and/or electrical insulation.
  • Epoxies:while they aren’t as durable as other materials when it comes to applying them on PCB boards, they are much more affordable to manufacture.

Since heat transfer is essential for the functioning of LED PCB boards, metals like Aluminum are commonly used as core materials

LED PCB Designing Rules

There are two rules to follow when designing LED PCBs. ʻUluakí kotoa, ensure that the LEDs will sit right on the circuit board holes and include the holes as part of the design. Uá, know to the distance between the holes. Ideally, to power the LED, you ought to have a minimum distance between the negative and positive terminals and the holes.

The next step is to save the design file in Gerber file format (industry standard format). The Gerber file should feature all the PCB layers as each layer represents a different aspect. You then need to save the dimensions and layer content of your PCB design in a text file. Send both the text file and Gerber file to the custom LED PCB manufacturer of your choice.

Once you get to buy your LEDs, ensure that they match your specification. The LEDs should also easily withstand the power that your SMD LED PCB board supplies

What Are the Design Techniques Applied for LED PCB Assembling?

  1. Pitch

This method is mainly used on LED displays, which typically have a symmetrical outer design. On the copper layer, one side is filled with pads that are arranged in a matrix, referred to as the LED layer. The other side consists of the copper componentsreferred to as the driver side. A smaller LED pitch means a better resolution and display. This design mainly depends on the LED pad specifications.

  1. LED Installing Holes

The holes in PCB boards are non-penetrating and have a diameter whose tolerance starts at plus/minus 0.05mm. The depth of the holes should never be beyond the board’s thickness minus 0.5mm with a tolerance of plus/minus 0.2mm. The conventional drilling angle lies at 130°.

  1. Distance Between the Outer Margins and Pads

There ought to be sufficient space between the outer margin and the margin pads, or else the LED PCB will develop issues like copper exposure and milling defects.

Testing of LED PCB

While there are many machines that are used in the testing stage, the most commonly used machine is the automated optical machine. It inspects whether there were mistakes committed during the assembly of the LED PCB boards, from problems with solder joints to issues with board components. Some of these issues can result in subpar connection quality or even no connection in the worst cases.

Misplaced components can easily connect to the part of the board that they aren’t meant to connect with, which is why testing is essential. Other ways for testing PCB boards for LED lights include automated X-ray inspections and manual checks.

Packaging each LED light PCB Board after Assembly

Packaging ensures that the electrolyte LED chips are linked with the outer LEDs. Other than providing chip protection, this precaution ensures optimized LED light luminance. It also ensures that the visible light is transported perfectly while maintaining the ordinary functionality of the diode chips.

Machine for Packaging LED PCB

The device used to package surface mount PCB devices is called a crystal precision solid machine. The LED boards have to be placed into the package with caution to avoid luminescence compromise. Poor packaging practices can easily result in issues with the LED’s brightness

LED Packaging Types

  • High-power LED
  • Side LED
  • Flip chip LED
  • Surface-mounted LED
  • TATAKI e mama
  • Top LED

What are Embedded LED PCBs Board and How They Work?

PCBs are essential to the performance of LED lights. They are boards on which LED components are soldered onto. They can be made from a wide range of material, such as fiberglass and metal. Other than physically supporting the LED bulbs, these PCB board for LED lights help transfer heat away from the electrical components.

This not only prevents their damage but also enhances their performance. For the effective functioning of the LED PCB board design, you need to bond the ceramic base and the thermal heat sink with a chip to produce light once electricity flows through the circuit board.

How Much Will Designing a PCB Cost You?

The cost of LED PCB manufacturing/assembling differs from one manufacturer to another. Luckily there are a wide variety of online calculators that could help you calculate the cost of your project. Ideally, the factors that will mainly affect the final cost include labor, lahi ʻo e koloa, delivery timelines, and the technology used.

Depending on your ideal number of units, the PCB assembly unit cost can fall anywhere between $10 mo e $50. Ka neongo ia, this is a rough estimate since costs vary between manufacturers. Simply put, getting a direct quote from the manufacturer is the best way to estimate the cost.

If you are looking to cut this cost, consider allowing some delivery leeway and ordering in large quantities. While large orders typically come with discounts, long delivery timelines could see you get a price break. Above all, ensure that you test your LED circuit boardsquality trumps cost any day.

What is the Most Preferred LED Light for Your Eyes?

Eye-care is essential if you want to optimize your eye health. Ideally, the best LED lights for your eyes are anything that mimics daylight. Choose LED bulbs whose color temperature stands at 5000-6500K since this is the typical daylight temperature. All the colors will look natural and sharp, not to mention that your eyes won’t tire easily.

How to Choose an LED PCB Supplier

While price is essential when selecting LED PCB assembly providers, it is barely the most important factor to look at. Focus on the value that their LED PCB assembly services provide to your project. Hangē ko ʻení, how much investment have they made into research development? Here are a few ways to identify great assembly providers:

  • Ask their previous clients for reviews.
  • Assess how quickly their customer support team is at responding to customers.
  • Test the quality of their circuit boards
  • Ask about the typical delivery timelines to ensure they match with yours.
  • Ask if they can easily deliver the bulk of your LED PCB order.
  • Talk to them about discounts and price breaks.

Give Your Customers Some Peace of Mind with LED Lights

There are no limits to what LED lights can do, from lighting households to helping with plant growth. With the benefit that LED lights provide, these lights will be around for a long time. Their environment-friendly nature makes them ideal for use in a world that cares about environmental conservation.

Why Choose Us for LED PCB Assembly

With over 14 years of experience in the PCB manufacturing and assembly industry, you can count on us to offer nothing less to top-quality LED printed circuit boards, meet your price and specifications and deliver your PCB on time anywhere you want. We also offer wholesale LED PCB board services. Over the year, we’ve produced countless PCBs with different designs for different customers. They include UV LED PCBA for the medical machine, UV LED PCBA for 3D printer, AC220V driverless LED PCBA, AC110V driverless LED PCBA, LED PCBA for street light, LED PCBA for tube light, LED PCBA for panel light, COB RGB LED PCBA for pool light, RGB LED PCBA for pixel light, LED PCBA for ceiling light, LED PCBA for the traffic light, and many more.

We’ve specialists in all types of LED PCB Assembly techniques with state-of-the-art equipment and materials to ensure your LED PCB function optimally and lasts longer.

Contact MOKOLight today for help with your LED PCB needs.

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