Overview of LED PCB Assembly
LED PCB assembly involves the integration of high-brightness light-emitting diodes onto specialized substrates engineered to manage extreme thermal loads. DuxPCB provides advanced assembly solutions featuring High-Density Interconnect (HDI) structures and Metal Core PCBs (MCPCB) that ensure operational stability in high-current applications. Our process adheres to IPC Class 3 standards, focusing on fine-pitch placement and specialized solder paste formulations that mitigate thermal stress in harsh industrial and automotive environments.
Thermal Management & Advanced Materials
Our engineering team specializes in substrates with high thermal conductivity, ranging from standard aluminum bases to advanced copper-core and ceramic (AlN/Al2O3) solutions. We utilize thin, high-performance dielectrics to minimize thermal resistance, allowing for maximum heat dissipation from the LED junction to the environment. For applications involving smart lighting controllers, we integrate Rogers and High-Tg FR4 materials to maintain signal integrity and prevent delamination under continuous high-temperature cycling.
Precision Component Sourcing & Binning Control
Consistent optical performance requires meticulous LED binning and component management. DuxPCB ensures that every assembly maintains color temperature (CCT) and luminous flux consistency through strict BOM control and automated optical inspection (AOI). We offer precision placement for components as small as 0201 and fine-pitch ICs, supported by 3D Solder Paste Inspection (SPI) to prevent common defects such as voiding or solder bridging in dense LED arrays.
Technical Capability Table
| Parameter |
Technical Specification |
| Base Materials |
Aluminum (6061/5052), Copper, FR4, Rogers, Ceramic, Polyimide |
| Thermal Conductivity |
1.0 W/m·K to 400 W/m·K (Copper Base) |
| Layer Count |
1 - 32 Layers |
| Copper Weight |
0.5 oz to 10 oz (Heavy Copper Capability) |
| Dielectric Thickness |
50μm to 150μm (High-Voltage Insulation) |
| Min Trace/Space |
2 mil / 2 mil (Fine Pitch) |
| Surface Finish |
ENIG, ENEPIG, OSP, Immersion Silver, HASL-LF |
| Max Board Dimensions |
500mm x 1200mm (Extended Strip Capability) |
| Assembly Standards |
IPC-A-610 Class 3, ISO 9001, UL Approved |
Why Partner with DuxPCB?
- 1. Solving Manufacturing Failures: We specialize in rectifying design flaws in high-power LED arrays that cause thermal runaway or premature failure—complex projects that low-cost vendors typically reject.
- 2. Precision Signal Integrity: For intelligent lighting systems, we provide controlled impedance and EMI shielding, ensuring that high-speed communication signals remain clean and reliable where competitors experience drift.
- 3. Mastery of Exotic Materials: Our technicians are experts in processing high-performance materials like Rogers and Arlon, guaranteeing zero-delamination and structural integrity in demanding aerospace and defense environments.
- 4. Advanced DFM Engineering: Our technical team conducts predictive Design for Manufacturability (DFM) checks to catch critical thermal path errors and layout inconsistencies before production, eliminating costly scrap.
Engineering FAQs
Q: What is the thermal conductivity limit of your MCPCBs?
A: We offer aluminum-based boards up to 3 W/m·K and specialized copper-core or ceramic substrates that can reach over 400 W/m·K for extreme power requirements.
Q: How do you manage LED binning for optical consistency?
A: We perform rigorous BOM verification and coordinate directly with suppliers to ensure all LEDs on a single board or across a batch come from the same color and brightness bin.
Q: Can you handle ultra-long LED strips?
A: Yes, our automated SMT lines are equipped to handle boards up to 1200mm in length, maintaining high precision and alignment across the entire span.
Q: Do you offer thermal simulation for new designs?
A: Our engineers can provide thermal analysis to suggest optimal copper thickness and via placement to maximize your design's lifespan and efficiency.
To initiate your high-performance LED project, upload your Gerber files and BOM through our secure portal for a comprehensive technical review and quote.
