English Views: 0 Author: Site Editor Publish Time: 2025-05-15 Origin: Site
Key Application Areas:
General Lighting: LED Lens with batwing distribution reduces glare; smart dimmable lenses support IoT control.
Automotive Lighting: Automotive-grade lenses withstand extreme temperatures (-40°C to 125°C) and support Adaptive Driving Beam (ADB) systems.
Backlight Display: Ultra-thin light-guide lenses (<1.5mm) enhance HDR effects in Mini LED TVs and tablets.
Medical and Agricultural Lighting: 450nm blue lenses used in endoscopy; 660nm red lenses improve plant PPFD to 300μmol/m²/s.
Industrial Inspection: Coaxial lenses (±1° parallelism) enhance machine vision for automated quality control.
These lens often require precision PCBA production processes to meet strict standards of accuracy, durability, and light uniformity.
Contact us for LED Lens PCBA solutions >>>
I.C.T has successfully delivered LED LENS SMT production lines to multiple global customers, demonstrating our global delivery capability and engineering excellence.
In June 2024, I.C.T successfully delivered and commissioned a complete SMT production line for LED lens assembly in Tajikistan, supporting the manufacturing of DOB LED lighting products. Our engineering team handled full installation, on-site calibration, and hands-on training for the customer's operators and technical staff, ensuring immediate mass production and reliable performance.
In November 2023, a full LED Lens SMT line was implemented at a customer site in Poland, serving the European LED lighting market. This line was used to manufacture DOB LED panel lights with strict optical alignment requirements. Again, I.C.T's engineers provided end-to-end support—from equipment setup to comprehensive production training—reinforcing our role as a trusted technical partner.
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The actual production of LED panel light products as an example: the maximum size of the product is 510MM * 330MM; according to the product information and the actual process requirements, the customer configure the following program line, taking into account the difficulties in the production process and efficiency.
LENS mounting process flow: PCBA spot UV adhesive → LENS mounting → UV adhesive curing
PCB Transfer ---------- ---------- Entry via PCB conveyor
UV Glue Dispensing ------ ------ I.C.T high-precision dispenser
PCB Transfer ---------- ---------- Post-dispensing buffer
Lens Placement -------- --- ----- multi-functional chip mounter with customised lens feeders and nozzles
PCB Transfer ---------- ---------- Between process stages
UV Curing ----------- ---- ------- I.C.T UV curing oven with high energy output for fast solidification
Cooling Conveyor ------- ------- Final transfer for cooling before storage or downstream process
1 Engineer
1 Operator
1 Quality Inspector (QC)
Adjustable according to production needs.
| LED LENS Production Line Configuration | |
| LED LENS Capacity | Estimated output of 600 pcs/hour (single panel lights) |
| Power | Line running power 11KW/H |
| Applicable products | Medium and high-end products can be satisfied, the maximum PCB width: 350MM |
| Line size | SMT workshop L20m*W5m size, the total area of about 100 square meters. |
Video: Lens Dispensing and Mounting Line Overview
The LED Lens market continues to expand, driven by:
Mini & Micro LED Integration: Lenses for AR/VR near-eye displays, tablets, and TVs.
Smart Lens Technologies: Electrically tunable lenses for adaptive lighting.
Advanced Optical Design: Full internal reflection (TIR), hybrid optics combining refraction and reflection.
Challenges remain, such as:
Dependence on imported high-end materials (e.g., automotive-grade silicone).
Mass production yield issues for micro-scale lenses.
Future Trends:
Intelligent Design: AI-assisted optical simulation to shorten R&D cycles.
Sustainability: Bio-based PMMA and mercury-free materials.
Integration: Combining lenses with sensors and thermal management.
Producing high-precision LED Lens assemblies requires overcoming several technical challenges throughout the SMT process. I.C.T addresses these challenges with advanced technology and years of industry expertise to ensure consistent quality and high yield.
During the SMT process, precise placement is critical—both the LED chips and optical lenses must be mounted with micron-level accuracy on the designated PCB pads. To achieve this, I.C.T utilises high-precision multi-functional chip mounters from South Korea, equipped with customised nozzles and dedicated feeders specifically designed for LED lens handling. This ensures repeatable placement accuracy across all units, especially important for products like DOB LED panel lights.
Before lens placement, UV adhesive must be dispensed in exact quantities onto the PCBA at pre-defined positions. The glue's flow behaviour and viscosity must meet tight tolerances for proper adhesion and optical performance. To ensure this, the UV glue is pre-heated based on its TDS (Technical Data Sheet) characteristics to optimise fluidity.
I.C.T deploys its self-developed high-speed, high-precision dispensing machines. These machines use pulse signals to control pneumatic jet valves, enabling uniform, consistent glue distribution even on densely packed or complex boards.
After lens placement, UV curing is essential to solidify the adhesive and lock the lens in place. I.C.T has developed its own high-energy UV lamp system, which delivers superior intensity and curing efficiency. This system is especially effective for curing challenging adhesives like UV40, ensuring strong, stable bonds without compromising cycle time or product quality.
As the global demand for advanced LED lighting increases, the need for high-efficiency, intelligent, and automated SMT production lines becomes more urgent. I.C.T LED LENS SMT production solution is engineered to support this trend, ensuring high precision and reliability for every application scenario—from smart homes to automotive systems.
Need a customised LED Lens SMT solution for your factory?
Contact I.C.T today – Your Dearest Reliable Partner in LED manufacturing technology.
