LED Manufacturing

Understanding LED technology

LEDs (Light Emitting Diodes) are a form of cutting edge technology that produces light using fundamentally different techniques from traditional lighting systems. While a thorough understanding of atomic physics is required to truly understand why LEDs function, a simplified version can be found here. For a more in depth explanation and discussion of the physics involved, please click here.

How we produce LED technology
Efficient production of high quality LED bulbs is the backbone of our business. We hope that you enjoy learning more about how we manufacture our LED light bulbs.

Printed Circuit Boards (PCBs)
Printed circuit boards (not to be confused with toxic PolyChlorinated Biphenyls!) are the substrate for the LEDs. PCBs are made from a base of “prepregs”, which are a non-toxic combination of glass fibers, cotton, and resin. Also integral are the electronic circuitry which are etched upon the board and determine the way the LEDs will eventually function. A PCB that we use in one of our lights is shown at right, with some LEDs already attached. Notice the copper etching and
the micro circuitry.

Individual LEDs
The first practical LED was developed in the early 1960s by Nick Holonyak Jr., and since that time the technology has continued to grow exponentially. Today, LEDs are built using thin wafers of semi-conducting metals, which have impurities added (“doped” in industry slang) to increase the amount of light produced. Different wavelengths of light (colors) can be produced by changing which impurities and substrates are used. Each individual LED wafer is placed on a metal lead, and is connected to the other lead with a very fine wire. The entire assembly is then sealed in plastic and attached to the PCB.

Assembling LEDs into light bulbs
Assembling LEDs into light bulbs is one of the most important steps. How the LEDs are installed determines what the light can be used for (for example, task lighting vs. diffuse lighting), and the care with which the components are assembled is critical to the overall quality of the bulb produced. Our factory takes the utmost care in this step, to provide you with the highest quality light bulbs.

Quality Assurance
In addition to testing each bulb, we measure the light output, to ensure that our bulbs emit the correct wavelengths of light and perform at our exact specifications. In addition to testing each light, we also make sure the light output of each batch of bulbs is uniform and that the light produced is as diffuse (or targeted) as we desire.

Technological Innovation
As LED lighting technology continues to mature, you can expect to see new technological innovations occurring virtually every week. This website (and especially, our Recent Headlines section) is a great way to keep up with the field. You'll also see the evolution of LED related technology, as it moves from the drawing board, to lab prototypes, and finally to our product lines and from there to homes across the world.

One recent breakthrough is the development of new faceted bulb covers that efficiently diffuses the directional light that LEDs produce.