Fully Automated SMT Solution for LED Lighting Applications

LED Lighting PCBA Applications: Driving Efficiency and Precision in Electronics

The global shift towards energy efficiency and smart lighting systems has propelled the LED lighting market to the forefront of electronics manufacturing. At the heart of this transformation lies the LED lighting PCBA (Printed Circuit Board Assembly), which ensures reliability, durability, and optimal performance.

LED Bulb PCBA

LED Lights PCBA

LED PCBA is essential in a wide variety of lighting products, including:

• DOB LED PCBA (Driver-on-Board): Streamlined power integration for compact and efficient designs.

• LED Lens PCBA: Offers precise optical control for streetlights and architectural lighting.

• Panel Light PCBA: Designed for uniform illumination in commercial and residential spaces.

• Downlight and Bulb PCBA: Used in high-efficiency ceiling and general-purpose lighting.

• Streetlight PCBA: Engineered to meet stringent outdoor reliability requirements.

Whether it's for streetlights, bulbs, downlights, or panels, the quality and precision of LED PCBAs directly influence product lifespan and energy efficiency. For manufacturers, ensuring high-volume, high-accuracy PCBA production is vital to remaining competitive in the LED lighting industry.

I.C.T Smart Factory Solutions for Full LED Lighting Production

Take the actual production of LED products as an example: the maximum size of the product is 510MM * 330MM; according to the product information has been and the actual process needs, for customers to configure the following program line, taking into account the difficulties in the production process and efficiency.

To meet the diverse needs of LED lighting PCBA production, I.C.T offers a fully automated SMT solution with high-speed, high-precision, and highly flexible configuration options.

✔️ SMT Process Flow:

• Solder Paste Printing → Printing Inspection → Component Placement → Reflow Soldering → Optical Inspection

✔️ LENS Mounting Process Flow:

• UV Glue Dispensing on PCBA → Lens Mounting → UV Glue Curing

✔️ Coating Process Flow:

• Conformal Coating Application on PCBA → UV Inspection → UV Curing

✔️ LED Bulb Assembly Process Flow:

• LED Bulb Assembly → Aging Test → Final Packaging

SMT Line Configuration

• Board Loader ——————————————— PCB Loading

• Solder Paste Printer ——————————— Solder Paste Printing

• PCB Conveyor ————————————————— PCB Transfer

• SPI (Solder Paste Inspection) ——————— Solder Paste Quality Inspection

• Reject Conveyor ————————————— PCB Sorting Transfer

• Pick & Place Machine —————————— Component Placement

• Conveyor ————————————————— PCB Transfer

• Reflow Oven ——————————————— Reflow Soldering

• Cooling Conveyor ————————————— PCB Cooling Transfer

• AOI (Automated Optical Inspection) ——— Optical Inspection

• NG/OK Unloader ————————————— PCB Collection (Pass/Fail Sorting)

Based on the customer's factory layout and renovation conditions, we optimised the production line arrangement to minimise modifications to the main power lines, air supply pipelines, and exhaust ventilation ducts. While ensuring an aesthetically pleasing overall layout, we also considered visibility for visitor walkways, allowing clients to clearly observe the production environment. As a result, the SMT line, LENS mounting line, COATING line, and LED Bulb Assembly line were carefully adjusted and repositioned accordingly.

Personnel Allocation

Based on the production line configuration and product requirements, the personnel allocation for the entire line is as follows:

• Engineers: 2

• Operators: 8–10 (SMT & Coating & Assembly)

• Quality Control (QC) Staff: 5 (SMT & Coating & Assembly)

The actual number of personnel can be flexibly adjusted according to specific product types and production demands.

Solution data

LED Lighting Production Line – Real Factory Footage

Watch how I.C.T's automated SMT line powers the future of LED manufacturing:

Overcoming Technical Challenges in LED PCBA Manufacturing

LED products often come with high demands for precision, reliability, and diverse component compatibility. I.C.T smart factory solution directly addresses the industry's biggest production challenges:

1. Precision Mounting

High-accuracy placement (±30μm) using Japanese and Korean pick-and-place machines ensures LED beads and lenses are accurately installed on PCBs.

2. Component Diversity

To handle varied component sizes and shapes, dual-machine solutions (JUKI + HANWHA) allow for both fine and bulky components to be efficiently processed.

3. Solder Paste Printing Quality

Precision printers and paste conditioning (warming and centrifugal mixing) ensure optimal stencil printing and minimal defects.

4. Reflow Soldering Reliability

The Lyra622 reflow oven offers uniform thermal profiles and gentle heat transfer to protect sensitive components.

5. Heat Dissipation Management

Gradual ramping in the reflow oven and small-loop hot air distribution minimise thermal shock during soldering.

6. Production Efficiency

Customized production lines match different product complexities, balancing cost and output.

7. Quality Assurance

Equipped with SPI and AOI machines, the line ensures consistent product quality through every step.

8. Controlled Environment

Cleanroom setup following ISO 14644 standards with temperature control (24±2°C) and humidity (40%–60%) ensures optimal process conditions.

Partner with I.C.T – Your Reliable LED PCBA Solution Provider

With decades of expertise in SMT technology and LED application solutions, I.C.T is committed to providing reliable, localised services to clients worldwide. Whether you're manufacturing high-performance LED bulbs, panel lights or smart streetlights, our fully automated solution offers the precision, scalability, and support you need to lead the lighting market.

Contact us now to customise your LED PCBA production line>>