Blog  /  7 Problems And Solutions Often Encountered In Led PCB Assembly

7 Problems And Solutions Often Encountered In Led PCB Assembly

PCB assembly in LED light is one of the revolutionary innovations that have made the energy-saving lighting technology near perfect.

By using the circuit board, the lighting companies can now device low heat dissipating, duster and moisture resistant, and low profile LED lights that are applicable in all spectrum of life. To go around this as a designer or even final user, you might need to find a custom led circuit board to power up your LEDs.

However, even with innovation, there are still loads of problems that undermine the LED lights' efficiency. Here are seven solutions for LED lighting PCB assembly that you need to look out for in any system.


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1.Control current


LED light, the soul of lighting globally, enjoy merits such as high illumination, long lifetime, stability, and low energy consumption. That is why the technology has wiped out some other contemporary lighting methods, such as halogen and fluorescent tubings.

But even with the merits, the technology came with one disadvantage that undermines its efficiency a great deal—a custom led circuit board tends to generate high heat energy. Thus, the system cannot cool efficiently through traditional means.

The custom LED PCB assembly uses metal core PCBs due to their high efficiency when it comes to problems related to heat dissipation. Some other companies use aluminum PCB. The metals have thermally conductive dielectric materials that conduct heat with unmanageably higher efficiency while at the same time dissipating heat.

When your lighting system emits large amounts of energy, you risk damaging the connected accessories. For example, LED lights in the aquarium tanks will emit heat to your waters hence causing pets to boil. PCB assembly caulks all these problems to make LED lighting technology flawless.


A PCB board for LED at close range

( A PCB board for LED at close range)


2. Welding LED Components


Among the things that one needs to take proper control or care of when doing PCB assembly are the welding components. For an LED light to work effectively and be as durable as they need to be, one must ensure that they welded on the right base. A ceramic plate is the most effective because it will minimize heating. A ceramic base is ideal because it will ensure durability and strength to the custom LED PCB.

When you are doing PCB assembly, there are some matters that you need to take into proper consideration. These are:

I.The solder bridge: when there is an unpredicted connection when you are soldering, it might lead to shorts circuits. You should, therefore, be careful when making any soldering connections.

II. Lifted components can also happen when you are soldering, so the manufacturer needs to be careful at all times.

III. Keep the soldering bit clean and neat so that you can get a proper joint, and this will also make you have adequate heat induction when soldering.

IV. Start with soldering the small parts and then move on to the more significant elements. Hence, it will make it easy for you to assemble the PCB.


LED PCB components on a ceramic material

(LED PCB components on a ceramic material)


3.Material Selection of LED PCB Board


Generally, the functionality, manufacturability, and life cycle of PCBs make LED lights rely on its construction. Therefore, the list of materials you chose for your board can either bury or enhance the whole system's quality and efficiency.

To develop an all-time efficient board, PCB manufacturers use a wide assortment of products ranging from substrates and laminates to Circuit Board Types. However, it is worth noting that only one material wrongly placed in the PCB can ruin the board's overall functionality. That is why material selection remains a significant problem in the LED PCB assembly.

So, what is the way forward? The best solution is to enlist flex, rigid, and customized boards from well- renowned manufacturers so that you can come up with a better board. And WellPCB is one of them. You can also acquire the already made parts and conjoin them together to form the PCB assembly boards.

Typically, the board consists of a series of layers that overlap each other. You can acquire the layers separately and join them together to get moving.

Focus on coming up with a thicker board. A thicker board will guarantee significant support to the connected devices with negligible risks of failure. A standard thick board usually is 1.6 mm. Anything less than that can compromise your PCB assembly's durability, quality, and functionality in totality.


A typical example of a PCB of an LED light

(A typical example of a PCB of an LED light)


Special Offer: $1 for 5 PCB Assemblies!

One requirement only: Order must be placed using a company account.
Please email [email protected] for details.
Special Offer: $1 for 5 PCB Assemblies!

4.Assemble LED PCB With Aluminum Base


As mentioned, LED lighting PCB boards generate intense heat when it runs. However, with the use of an aluminum base, you will stand a chance to increase the functionality of the system since:

I. It increases the stability of your PCB. It is because of the heat transfer that is better than other materials, and therefore, other parts will not be affected. The heat will move away from sensitive parts, leaving them safe.

II. Aluminum is strong and durable and can stand high temperatures. It is an ideal option when it comes to withstanding the high heat dissipation.
III. In addition to being durable, aluminum is light in weight and more comfortable handling and even transport.

IV. Aluminum is less expensive as compared to many other boards. It is also recyclable and is, therefore, environmentally friendly.

V. Aluminum will guarantee a longer operating time because it has better heat transferring capabilities and can, therefore, work at a low temperature. Aluminum will increase the lifespan of your PCB.
VI. Heat moves much faster when using aluminum. Thus makes it function more efficiently, and it will not exceed the temperature that has specified for it.


PCBs of LED lights assembled

(PCBs of LED lights assembled )


5. Embedded LED PCB


When doing a custom LED PCB assembly on small and thinner electronics, embedded LED PCB is most appropriate to use at this time. It's because they allow for more straightforward merchandise findings so that the assembly result is precise and clear. The lights apply to medical devices, low lighting environments, and also some aviation and marine appliances. The following are some of the benefits of using an embedded LED PCB:

I.Dust resistance and even moisture resistance

II. They are lightweight and not easily noticeable

III. They are available in color, sizes, and light intensities

IV. They have a lower backlight coat and membrane switch

V. They consume deficient power and are therefore extremely energy-saving.

VI. They work better on silver and copper flex membrane switches.


6.Single Point, Surface Mount, And Integrated LED


These are LEDs designed by manufacturers so that they can meet the users' specifications. These LEDs are available in different colors and sizes too. They need to install in any chosen area, and they create color while also reducing the size of light produced. These lights have their advantages and disadvantages.


1. The light source is optimized

2. Fixtures have an added value

3. Making a new design is much easier when dealing with integrated LED


1. They have expiration dates

2. They might be difficult to replace

3. Most of them do not have solid warranty covers


7.Some Requirements For Custom LED Lighting


It would help if you didn't do shoddy work when you are working on custom LED lighting. This factor is because this work is sensitive, and one needs to pay attention to each little detail. PCB assembly is slowly gaining popularity, and with lights getting even smaller as time goes by, there is a lot of consideration to their perfection. To make a proper custom LED lighting, you need the following:

1. First, you need the appropriate expertise when dealing with LED Lighting PCB assembly, and this is because any slight mistake can make a PCB to stop working or even a short circuit.

2. Ensure that you have soldering material that is of top-notch quality, and that will ensure that your work does neatly and without unnecessary mistakes.

3. Male sure all your documents are also of good quality so that you can custom make a PCB lighting that is durable and stable.

4. Because of the high heat you will experience as you work, you will need to take greater preventive and protective measures for precise results.

5. Proper knowledge of lighting and the growing technology is also a must. Proper education will ensure that you move with the technology and the changes or improvements that need do at any time.


an engineer working on a PCB board for led

(an engineer working on a PCB board for led)



As we speak, PCB has advanced into tiny, multi-layered, and sophisticated systems that hardly resemble their predecessors. The sophistication has also come with high efficiency for slimmer and faster devices in the world. Finding that partner to work with saves you lots of time and money, and WellPCB got your back.
OurPCB has years of experience producing PCB for LED lightings used for various purposes and has the certification. We work round the clock to ensure that you get the best possible custom led circuit board there is. Reach us today.



Special Offer: $1 for 5 PCB Assemblies!

One requirement only: Order must be placed using a company account.
Please email [email protected] for details.
Special Offer: $1 for 5 PCB Assemblies!