How to Produce LED Bulbs, The Complete Guide

If you’ve been using incandescent bulbs, or LED lights for a while, you might have noticed a shift from the old normal bulbs to LED lights. This shift is because LED lights are becoming more popular, durable, and affordable.

With their long lifespan of about five years, and energy saving properties, it’s not a surprise they are quickly replacing the old traditional bulbs.

As the demand for the LED bulb is constantly increasing, learning how to produce it is never a bad idea.

In this article, I will walk you through on how to produce LED bulbs, and the materials required.

What is a LED?

LED is an abbreviation for “light-emitting diode”. It is a semiconductor that emits light when a current passes through it.

LEDs are normally used for office or decorative lighting, as they offer more benefits than the old normal bulbs.

They produce less heat, save more energy, and last very long. They also produce several lighting colors and other benefits. You will be missing a lot if you are not using LED bulbs.

But since a single LED can not illuminate a large space, a combination of LEDs are usually necessary.

In most cases, we use surface mount device LEDs as they are more compact, and equally produce excellent lumen.

The LEDs are fixed on the PCB and covered with housing.

Why should I be interested in producing my own LED bulbs?

LEDs are quickly becoming the new go-to light bulb. They have a lifetime of up to 50,000 hours and produce a vast amount of colors.

Knowing how to produce it will not only help you save money, it will also open a new business opportunity for you.

Materials required to produce a LED bulb

To produce a LED light, you need the following materials:

  • Light-emitting diode (LED)
  • LED drivers
  • Printed circuit board (PCB plates)
  • Aluminum base
  • Aluminum pin
  • Screw
  • Housing
  • Heat paste
  • Cover
  • Sol tape.

Required tools

  • Pliers
  • Soldering iron
  • SOLDERING lead
  • Screw driver

Components of an LED bulb

Light-emitting diode (LED)

LED driver

The driver controls the amount of current that flows in and out of the LED.

there are three kinds of LED drivers:

  • Regulated circuit drivers: You can use zener diode as regulator here.
  • Unregulated driver: Requires no regulator
  • Regulated driver with an IC: This requires an IC to build the driver.

For every circuit driver, you can use either 4 diodes for full bridge rectification, or a rectifier itself. Rectifiers convert alternating currents (AC) to direct currents (DC).

The driver comprises:

  • Rectifier for converting AC to DC
  • Capacitor to filter out ripples and stubborn AC voltage that persists after rectification
  • Resistors to step down voltage
  • Zener diode for regulation
  • Metal oxide varistors (MOV) to protect the circuit from surge.

Printed circuit board

Housing

How to produce the LED bulbs

Producing the LED bulb is easy once you have acquired the required materials. Just begin to assemble it.

Place all the materials on top of a table and solder the LEDs on the provided space on top of the PCB plate.

Pay attention to the polarity while soldering the LED. Identify the positive and negative terminals of the LED, and solder +ve to +ve and _ve to -ve.

Pick a housing, insert the driver’s outlet cable into it and place the soldered plate on top and solder. The driver comes with two input AC wires, two output DC wires.

Solder the +ve of the driver’s outlet cable to the +ve of the LED plate, and the -ve to the respective negatives.

Using a sol tape, tape the back of the driver if you are using aluminum housing to prevent electric shock.

Insert the driver input cables into an aluminum base (pin or screw) and pay less attention to the polarities.

Apply heat paste at the back of the LED plate for proper heat description.

Screw the LED plate on top of the housing and cover it. Fix the bulb on a lamp holder and test it.

Note: Production of other categories of LED lights such as flood light, street light, panel light, tube lights, and other types of LED lights passes this same process. The only difference here is that they don’t use aluminum base.

They make use of a +ve and -ve cable that is connected to the power source.

FAQ

How is LED different from incandescent bulbs?

The LEDs are different from incandescent bulbs in the following ways:

LEDs have electrons that flow to generate photons (light) while the incandescent glows with filament.

LEDs emit light from only one direction, while old bulbs generate from all directions.

While LEDs emit little heats, incandescent emit about 90% of its energy as heat.

LEDs have a long life span compared to traditional bulbs.

Do LEDs save energy?

Yes, LEDs save more energy than filaments because diode lights require less energy to glow.

A bright LED flood lamp of 12 watts can light up an output equivalent to a 50 watt incandescent bulb.

If I replace my old bulbs with LEDs, what should I do with the old ones?

If you replace your old bulbs with LEDs, never throw them away instead, recycle them.

These old bulbs contain mercury vapor that can pollute the atmosphere when released into it.

Instead of throwing them away, gather them carefully to your local hazardous waste center.

LEDs don’t contain mercury and may be thrown away however, they are more useful to recycle them.

That’s it in my complete tutorial on how to produce an LED bulb. Hope this helps? let me know your opinion in the comment section.