LED Lights Manufacturing Process

The LED manufacturing process

The LED lights manufacturing process is a complex procedure made up of three main steps: LED chips, LED package, and LED lamp. Each step must be executed to the highest standard to ensure quality control and product consistency.

The process begins with the manufacturing of the LED chip. First, the semiconductor material is grown in a high-pressure, high-temperature chamber, where elements (gallium, arsenic, phosphor) are purified, mixed, and liquified into a concentrated solution. Once combined, a rod is placed into the solution and slowly pulled out. After the rod is removed, the solution quickly cools and begins to crystalise to create a long crystal ingot. Next, the crystal ingot is sliced into semiconductor wafers, each sanded and cleaned to remove any dust, dirt, or organic material.

The semiconductor wafers are then layered up and diced into small segments called chips. The chips get separated and packaged into individual LED packages. The LED package acts as a casing that holds the chip, bond wire, and phosphor layer. The packages allow the LED chip to emit bright white light. 

Finally, the LED packages are mounted onto a printed circuit board and integrated into the product. The most common LEDs in the home are pendant lights, flush ceiling lights, and spotlights, but the opportunities are endless when it comes to integrating LED lights into products. With integrated LED lighting fixtures, manufacturers can market more exciting products offering Smart functions, increased design opportunities, better quality lighting, longer lifetime, and improved energy efficiency.