What is Process Flow of LED Manufacturing Facility: From R&D to Final Assembly and Testing? | LEDRHYTHM

June 09, 2023


Ledrhythm light fittings are unique branded products "Made in China" of highest quality standard which you can rely on. Every single light fitting of our product range is an original Ledrhythm product. Designed and engineered by our own engineers, produced using own tools and 100% quality approved.

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Through the following process steps, LED manufacturing factories can produce high-quality, high-efficiency LED lighting products to meet market demand and contribute to energy conservation and environmental protection. This process requires meticulous design, accurate operation and strict quality control to ensure the performance and reliability of LED products.


The process flow of the LED manufacturing plant begins with the efforts of R&D engineers. They are responsible for researching and developing new LED products, from designing prototypes to verifying functions and performances.

Our engineers use advanced CAD systems to design new luminaires, as well as optimize and modify current products according to individual customer needs. In the process, our expertise in the field of lighting for more than 15 years, and the cooperation with experienced material experts.

With thermal simulation programs, we are able to achieve perfect thermal management for each luminaire. Sample production due to in-house R&D department, via 3D printing and all manufacturing departments.

R&D engineers work closely with the team to ensure the innovation, reliability and manufacturability of LED products to improve efficiency and quality by utilizing advanced technology and software tools.


The R&D laboratory is the base of creativity and innovation of R&D engineers. Our luminaires as well as components and materials are tested in our own laboratory center where they conduct raw material screening, circuit design, optical performance optimization and thermal management research for LED components, including Integrating Sphere Tester, Distributed Photometer, Lightning Surge Generator, Hot and cold impact machine, IP testing machine and other precision instruments. Dustproof and waterproof chambers are included for checking the IP rating of the luminaire, including underwater tightness testing. Calorimetric measurements for checking the maximum permissible ambient temperature, low temperature tests in climate chambers and material aging tests, especially for explosion-proof luminaires, complete the test program for ledrhythm luminaires. Through experiments and tests, R&D engineers can verify design concepts and technical solutions, and provide guidance and support for subsequent manufacturing processes.


The Tooling Machinery Manufacturing Department is responsible for designing and manufacturing special tooling and mechanical equipment for the LED manufacturing process. According to the requirements of R&D engineers, they design and manufacture the automation equipment required on the production line, including growth equipment, wafer cutting equipment, packaging equipment, etc. The high efficiency and stability of these devices are crucial to ensure production efficiency and product quality.

Stamping, cutting, bending and welding of metal parts is performed on most modern machining centers and welding robots. This results in housings, reflectors and mounting accessories made of sheet steel, aluminum and stainless steel in different shapes, sizes and specifications.

The tools required for punching, cutting and bending are produced and maintained in the in-house tool shop. This provides us with flexibility and independence, enabling us to respond quickly and flexibly to our clients' needs.


All of our luminaire housings and reflectors in glass fiber reinforced polyester are produced on in-house molding machines. Drawing on decades of expertise, we understand the optimum interaction between temperature, pressure, pressing time and materials to produce highly durable luminaire housings.

Polyester molding machines and foaming equipment are used in  LED manufacturing plants to encapsulate and protect LED chips. The polyester molding machine encapsulates the LED chip in a transparent polyester glue by injecting polyester resin into the mold, which provides mechanical protection and moisture resistance. Foaming equipment is used to inject special foaming materials into the LED lamp housing to provide thermal management and waterproof functions.

After proper storage, these enclosures, as well as most die-cast aluminum enclosures, are supplied with foam polyurethane or silicone gaskets in a fully automatic dispensing system. Individual dispensing and foaming settings provide a perfectly fitting gasket for each shell and lid.


During the LED manufacturing process, powder coating and wet coating are used to provide protection and decoration to the housing of LED luminaires. Powder coatings are usually applied by electrostatic powder coating technology to form a uniform protective layer, providing wear resistance, corrosion resistance and weather resistance. Wet paint is applied to the surface of the luminaire by spraying, rolling or dipping, providing a wide range of color options and special effects.

All our metal and die-cast housings as well as reflectors and other metal parts are powder coated in our most modern, energy efficient and environmentally friendly fully automatic powder coating plant. Every RAL or DB color is possible according to customer preference.

For powder coatings in small batches, especially in special colors, the factory also provides a manual room.

The polyester shell in the outdoor area is subject to high loads due to UV radiation and weather influences. Over time, this can lead to corrosion of the housing surface, with unsightly consequences. We therefore supply polyester exterior lighting with a UV protective coating (on request), which is applied in a separate wet paint booth.


In the final stage of the LED manufacturing process, LED chips and components are installed into the luminaire through a delicate assembly process. Assemblers assemble components such as chips, heat sinks, circuit boards, lenses and lampshades according to the process flow. After the assembly is completed, each lamp will undergo strict testing and quality inspection, including tests on luminosity, electrical performance, temperature and waterproof performance, etc., to ensure that the product meets the standards and customer requirements.

Through the above process of R&D, manufacturing and testing, the LED manufacturing factory can provide high-quality and high-efficiency LED lighting products to meet market demand and contribute to energy conservation and environmental protection.

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