How to reduce the cost of LED lighting products

Even through the price of LED lighting products is cheaper than before, they are still unaffordable for many customers and industrial users to purchase and much expensive than incandescent lights and fluorescent lights. LED lighting is consist of many components which need more cost and technical to manufacture, and the design and production cost of LED lighting systems make it expensive compared to conventional lights. As a new type of energy-efficient lighting, reducing the price has become one of the most important issues of the popularity of LED lighting systems. So, how to reduce the manufacturing cost of LED lights has become a tremendous challenge for the manufacturing industry.

There are many ways to reduce the design and production cost of LED lighting products. Since many components cannot be replaced and the cost is constant, many manufacturers will shift towards the LED chips, LED packages and in display panel technology to reduce the cost of LED lighting products. The advanced LED chip and packaging have had good beneficial impact on the number of LEDs used, which has helped to cut down production cost of LED lighting products.

The first way, using advanced LED chips to reduce the number of LED chip. The LED lighting with general brightness need several LED chips, and the more wattage, the more LED chips required. So many manufacturers require LED lights with one chip, which means that LED chips should have significant increase in efficiency. University of bath researchers have made an innovation, they incorporated nanostructures into the LED chips, which enabled the semiconductor materials to grow in a regular crystal structure. It was found that the efficiency and light output are better, and less light is wasted. The nanostructures help to have more control over the direction of light given out by the LEDs, and allow them to focus beams of light.

The second way is low-cost plastic LED packages. The advancement in plastic LED packages will allow the LED lighting to remain long-term reliability, lumen maintenance and color stability. What’s more, the low-cost plastic LED packages will greatly reduce the production cost of LED lights, providing affordable products for customers. As a newly developed LED package, PLCC can distribute light and heat through LEDs distributed spatially, and its features can improve the brightness. However, the designers and manufacturers have to cautions and ensure that the use low- and mid-power LEDs which are made of reliable materials. 

The third way, using cost-effective silicon wafers. Purdue University researchers have developed a method of using cost-effective silicon wafers, replacing the expensive sapphire-based technology. Manufacturers will prefer silicon to produce LED lighting for the low-price silicon will ensure the low-cost products, which will bring LEDs into competitive pricing as compared to fluorescent lamps and incandescent lights. Many industries have begun to scale up the LED lighting in the help of silicon wafers. At the same time, the silicon wafers have better heat dissipation than sapphire, reducing damage caused by heating, which is likely to improve reliability and increase the lifetime of LED lighting.

Actually, as long as technology continues to progress, it is not difficult to reduce the design and production cost of LED lighting products.