An A-Z Guide on LED Lights Production Flow at ShineLong LED Company
Now:
It’s natural to ask; how are LED lights made and how does ShineLong LED ensure that lights fixtures meet quality and performance standards?
If you’ve been wondering the same thing, then you’re in the right place.
Note:
To produce the best products in the market, we often carry out meticulous quality and performance checks at every stage of the manufacturing process.
And:
In doing so, we can provide our customers with the very best LED lighting fixtures in the market today.
So, how do we actually do it?
Well, here’s everything you need to know about our LED lights production flow:
ShineLong’s LED Manufacturing Process
Get this:
Manufacturing is a multifaceted process comprising several sub-procedures.
This is where we sort, process, and refine raw materials to come up with the different types of LED fixtures available on our catalog.
Note that:
Every bit of our manufacturing process is carried out or supervised by highly-trained professionals using the latest (most advanced) technologies and machinery in the lighting industry.
And this is how ShineLong LED lives up to its promise of producing the best fixtures on the market today.
Now:
Here’s a look at each stage of our manufacturing process and what goes on…
Once this process is complete and the LED Wafer and Substrate welding layers are fixedly connected, the final product is usually a structure that not only radiates heat easily but is also optimized for best performance.
2. LED Wire Bonding
Here:
Our main goal is often to connect the signals from our light-emitting diode (LED) chips.
Note:
Most LED failures (e.g. delamination, pad pealing, and cracking) are usually a result of faulty, inferior-quality wire bonding or issues emanating from this sub-process.
And that’s why we believe that it’s always important to be scrupulous during this procedure.
How do we do this?
Well, for starters, ShineLong LED uses industrial gold (99.9999% pure) for wire bonding.
Why?
It’s mainly due to the fact that Gold is a great conductor, strong/durable, and does not rust easily; and this guarantees a longer connection lifespan.
Impressive, right?
3. LED Sorting
Now:
Just as the name of this process implies, this stage of our manufacturing process involves sorting LED beads.
This process is usually done automatically using a spectrophotometer to group similar beads together.
Sorting is done according to:
- Current.
- Voltage.
- And Color.
Once complete, all beads with the same specifications/qualities are usually connected to each other as a strip awaiting the next step.
So:
To avoid contamination and damage, all our LED chips are packed into vacuum bags. Doing so helps to shield them from contaminants like dust and water vapor.
After this is done, the last process in our manufacturing procedure is usually testing.
5. LED Testing Process
Note that:
Testing is an integral part of our LED manufacturing procedure.
This helps us to check for production line issues and also whether the LEDs meet our quality and performance standards.
How do we execute this?
Well, the testing process is achieved in three simple steps:
a) The Baking Process
Now:
This is a very important testing procedure.
Since LEDs – just like other electrical devices – contain moisture-sensitive components, it’s important to ensure that there is not water vapor within or around them.
Hence, the Baking Process.
Here, the main goal is to dehumidify the components by subjecting them to carefully controlled heating.
Once that’s done, we move on to the next test.
b) Light Color Matching
Yes!
Aside from moisture removal, we also have to test the LEDs to check for light consistency. We understand that failure to do so can result in multi-colored, uneven lighting by these fixtures.
ShineLong uses modern technologies to ensure that all our LEDs produce the right colors and intensities at all times.
c) Microscope Testing
The last testing procedure in our manufacturing process is usually to check if everything is in place.
And:
That’s why we use specialized microscopes to check whether each LED Wafer has been placed correctly and is working optimally.
Our Surface Mount Technology (SMT) Process
I know you’re probably wondering:
What is Surface Mount Technology (SMT)?
So, here’s a quick answer…
Surface Mount Technology (SMT) is a development technique that involves mounting electronic components onto the surface of a PCB (Printed Circuit Board).
Why SMT?
Well, it’s cost-effective and improves production flow efficiency.
Anyway:
Here’s a rundown of everything we do during our SMT process:
1. Preparations
This mainly involves preparing all the materials and components we’ll be using.
And:
To ensure that we maintain high levels of quality, we also inspect the Surface Mount Components and the PCB to check for flaws.
That means ensuring that all the gold solder pads on the PCB are correctly placed and ready for mounting.
2. Stencil Preparation
In this step:
We ensure that our stencil is working correctly and is ready for solder paste printing.
Note:
The stencil is supposed to be positioned in-line with the solder pads on the PCB.
3. Paste Printing and Placement
Now:
This is when we do the actual printing; i.e. temporarily attaching the Surface Mount Components to the PCB’s solder pads using a suitable paste.
This process is quite delicate and that’s why we use specialized equipment including highly accurate pick-and-place machines.
And:
Once that’s done, we move on to the next phase of our production flow…
ShineLong’s Reflow Soldering Process
You might be wondering:
What exactly is Reflow Soldering and why is it important?
If so, it is a process where we use solder paste to temporarily hold the Surface Mount Components onto the PCB’s solder pads while we subject the entire PCB assembly to controlled heating,
Basically:
The entire assembly is placed on a conveyor and passed through our soldering oven’s different zones.
In a nutshell, here’s what happens:
- Zone 1 (Pre-Heat)– Here, the temperature is raised gradually but also simultaneously for all components of the assembly. Depending on the nature of the assembly, temperatures can be raised at a rate of 1-2℃ per second to a maximum of 160℃.
- Zone 2 (Soaking) – In this zone, the assembly is subjected to a constant heat temperature of between 140 and 160 degrees Celsius for about 90 seconds.
- Zone 3 (Reflow) – Here, the temperature is then ramped up to around 230 degrees Celsius at a rate of 1 or 2 degrees per second. Once the maximum temperature is achieved, the tin in the paste will melt to create a strong bond between the components’ leads and the PCB’s solder pads.
- Zone 4 (Cooling) –This is done to ensure that the assembly comes out of the conveyor without defect and that the solders freeze solid to provide a strong, unbreakable bond between the components and the PCB.
Impressive, right?
Thereafter, we do a little cleaning and final inspection to make sure that everything is in place and that there are no flaws in the assembly.
Any defects are then fixed, and once we are certain that all is well, we move on to programming and testing.
Device Programming Process
Get this:
There are a few procedures and algorithms that we often program into the fixture.
Basically:
These are the algorithms that help the fixture to execute certain functionalities including dimming, light color changing, and so on.
Here:
Our goal is to ensure that the fixture offers you more convenience, flexibility, and efficiency during use.
That way you get better value for your money.
Quick Testing Process
Now:
Once programming is complete, we test the assembly to ensure that the fixture is working flawlessly and as expected.
This even involves doing a “Power On” test.
And:
If the fixture turns ON and performs as expected, then it means that everything is A-Okay.
Hence, the commencement of the final assembly.
Lights Assembly Process
So:
This is the part where we bring all the major parts of a light fixture together including the housing, PCB assembly, power supply module, covers, end caps, and then run several tests on the fixture for quality and functionality purposes.
Here’s everything that goes on during this process:
1. PCB Board Welding
This involves welding any secondary components and wires onto the PCB board. That way the fixture will be able to function optimally in real-life environments.
2. Wiring in Alu Housing
Here, all the wires connecting to the PCB board, power unit, and switch are carefully placed within and around the Aluminum housing as per the design. Our goal is to be neat and organized. The last thing anybody wants is to have a fixture with wires lying around everywhere.
3. Connecting the Power Supply
This is when we place/insert the fixture’s power supply unit into the Aluminum housing. This unit is very important because it helps to regulate the electrical current going to the PCB and can also be used to execute certain features/functions of LED lights including dimming and color temperature changes.
4. Covering the Fixture
Once all the internal components of the LED light have been correctly placed, the last step in assembly is usually to cover the fixture. Here, we use the PC cover and end caps to secure the fixture’s components inside that aluminum housing. Plus, in most fixtures, the PC cover also acts as a diffuser for evenly-distributed lighting.
By now:
The fixtures are fully assembled and ready for shipping. But, before we pack them, we have to do a final test run just to be sure we didn’t miss anything.
5. Final Performance and Functionality Testing Process
Obviously:
Once the fixture is fully assembled, it’s wise to check whether it lives up to the standards set. And that’s why we subject our fixtures to more gruesome tests.
In doing so, we can comfortably give guarantees on the performance, durability, and value that our fixtures offer you.
So, what exactly do we test?
Test Process:
Lighting Test
Yes!
The first thing to check is the lighting. Here, we want to know:
- Whether all LED beads are lighting up and with the same intensity?
- Is the fixture is yielding sufficient flux as per its specifications?
- Whether there are any color differences within the fixture?
- Lastly, if all the LED features like dimming and color manipulation are fully functional?
If everything checks out, we move on to the next test…
High-Voltage Test
Now:
The primary goal of this test is to answer one question; can the LED fixture handle high voltages or unexpected power surges?
We all know the problems that come with an unstable power supply. And to ensure that your new fixtures are protected from this, we subject them to a high-voltage test before shipping out.
That way:
We can be sure that you’re receiving a durable and robust lighting fixture that’s worth spending money on.
Waterproof Test
Note:
All our fixtures come with an IP (Ingress Protection) rating. Therefore, we usually test each of them with water baths and moisture exposure to check whether they conform to their assigned IP rating.
Here’s everything you need to know about Ingress Protection.
Aging Test
We also carry out a specialized aging test(more than 24 hours for all mass order products) to determine the estimated lifespan of the fixture under optimal conditions.
This not only helps us to give accurate lifespans for our lights but also improves their efficiency and stability.
Insulation Test
Is it safe?
Yes. The last pre-packaging test is usually to test whether the fixture is fully insulated and safe to use. Obviously, the last thing you want is to spend money on an LED that has an electrical current leak.
Anyway:
If the fixture passes all these tests, it’s then packed and prepared for pre-shipping inspection.
The Packaging Process
Now:
As an experienced LED light manufacturer, ShineLong understands the real importance of proper and secure packaging of finished light fixtures.
Our primary goal is to ensure that your order gets to you in good shape and form; just the same way it left our manufacturing plant.
And:
That’s only possible if the packaging is done right.
Therefore, despite making suitable packages for our LED fixtures, we also subject the packed LEDs to a series of vigorous tests just to make sure that nothing gets damaged or deformed during transit.
We achieve this by conducting two quick tests; namely:
Test Process:
The Vibration Test
So:
This is usually meant to check for any loose components and also whether the fixture will be able to withstand harsh shipping conditions; that may cause a lot of vibrations.
In simple terms, the vibration test is often a simulation of shipping conditions over rugged terrain.
Therefore:
If an LED fixture doesn’t fall apart or get damaged after this test, then it is safe to assume that it will not be affected in any way during shipping.
The Drop Test
Get this:
The carton drop test is one of the most important inspection processes in our production flow.
Why?
Because it helps us to check the safety and security of the fixture before shipping; that way we can avoid “Dead on Arrival scenarios.”
Regardless of how many precautions we take to avoid dropping these fixtures, we cannot rule out the fact that other handlers (shipping, landing port, and courier services) might accidentally drop them.
So, to make sure that no harm comes to your order, we use international standards including ISTA (International Safe Transit Association) and ASTM (American Society for Testing and Materials).
And the best part is that this test is easy and fast to achieve.
Now:
Every fixture that has passed all the tests above and checked out is usually labeled as “ready for shipping” and is processed for dispatch.
In Summary…
Evidently:
We don’t play around when it comes to the quality and performance of our LED fixtures.
Yes!
ShineLong LED takes pride in offering you the best products you can find on the market.
Our production flow is filled with quality inspections and tests at every stage; just to make sure that the final product is not only flawless but also manufactured under international standards.
Impressive, right?
Anyway, if you’d like to know more, place an order, or start your customized project with us, feel free to contact us. We’ll be more than happy to hear from you. Thanks.
