Sparkfun has pretty interesting to look at article How LEDs are Made. How LEDs are Made factory tour article shows how LED supplier YunSun (Shenzhen China) makes LEDs. YunSun buys their LED dies from Taiwanese company (thin sheets contains thousands of LED dies). LED wire bonding machine attaches a hair-thin gold wire from the top of the LED die to the anode lead. Once the wire bond is in place and the adhesive is cured, the lead frame gets placed in the LED mold and gets epoxy resin pushed in around the lead frames. One of the first things that surprised the writer was that the entire operation was done in open air (no clean room technology). Maybe you could do this in your basement with right tools…
5 Comments
Tomi Engdahl says:
The majority of the LEDs are still based on gallium nitride, which is usually grown safiirialustalle. Many would like a cheaper platform for silicon and is now an English Plessey Semiconductor demoed 6 inch Silicon wafers made of LEDs that produce 5 watts of light output.
Plessey manufactured by six-inch reel, which is filled with 4.5 x 4.5 mm 5-watt LEDs. This is essentially a technical demonstration of “silicon led” preparation was demonstrated. Plessey manufactured LEDs emit blue light from 400 to 480 nanometers.
Source: http://www.etn.fi/index.php?option=com_content&view=article&id=2083:suurikokoisia-ledeja-piikiekoilla&catid=13&Itemid=101
Tomi Engdahl says:
What do fireflies and LEDs have in common?
http://www.edn.com/electronics-blogs/led-zone/4441963/What-do-fireflies-and-LEDs-have-in-common-?_mc=NL_EDN_EDT_EDN_funfriday_20160506&cid=NL_EDN_EDT_EDN_funfriday_20160506&elqTrackId=e80025566b5b48d093b26d74b3311d50&elq=31b42a31c23e4cd3bfe96fe431fbf6e7&elqaid=32161&elqat=1&elqCampaignId=28073
The incredibly resilient and strong structures made by nature are often at the heart of scientific research. Back in 2012, South Korean scientists took observations made of fireflies to make an improved and less expensive LED lens.
The basis of the work is to mimic the bioluminescent organ for lighting apps. The organ’s bioluminescence is used to attract mates. By using a scanning electron microscope and numerical analysis, experiments revealed that the highly ordered structure reduces optical impedance between air and the cuticle, becoming an anti-reflective layer, and minimizing the loss of light while improving efficiency.
The discovery led to an artificial version that was used as a high-power LED lens. The structure of the firefly’s underbelly was the subject of their initial paper, “Biologically inspired LED lens from cuticular nanostructures of firefly lantern,” published in Proceedings of the National Academy of Sciences.
Biologically inspired LED lens from cuticular nanostructures of firefly lantern
http://www.pnas.org/content/109/46/18674.full
Cuticular nanostructures found in insects effectively manage light for light polarization, structural color, or optical index matching within an ultrathin natural scale. These nanostructures are mainly dedicated to manage incoming light and recently inspired many imaging and display applications
The nanostructures on an LED lens surface were fabricated by using a large-area nanotemplating and reconfigurable nanomolding with heat-induced shear thinning. The biologically inspired LED lens, distinct from a smooth surface lens, substantially increases light transmission over visible ranges, comparable to conventional antireflection coating.
Tomi Engdahl says:
Video of LED Factory
https://www.youtube.com/watch?v=piUMJ6sfZvs
LED factory. LED dip 3mm/5mm/8mm/10mm.
Tomi Engdahl says:
RGB LED manufacturing
https://www.youtube.com/watch?v=M-EV5dKtalk
This video shows the manufacturing process of RGB LED’s
Tomi Engdahl says:
LED factory
https://www.youtube.com/watch?v=wm-6nL5odyc
specialized in making digital led strip and pixel module.