Top quality from China

Much of our contact with manufacturers takes place via email and phone. However, sometimes we meet in person at trade shows or on-site visits. This was the case in March during a visit to China.

We got a behind-the-scenes look at various manufacturers. Each factory had its own unique setup, but what they all shared was a commitment to high quality. Everything is subjected to quality checks—starting from the incoming raw materials to the packed lighting products and every production step in between.

Production Process

Before LEDs are mounted on a circuit board, the boards are first checked for imperfections. This is done visually by a machine that compares the board to an image in its memory. Only then are the components mounted on the board, which is then checked again.

A selection of power cables is subjected to a durability test. These cables are clamped into a kind of cage, with a weight attached, which repeatedly rolls the cables back and forth thousands of times. Only after approval can the cables be mounted onto a circuit board and placed inside a housing. Afterwards, the LEDs are tested to ensure they light up properly.

The lens is secured onto the housing using the best adhesive (also tested). Then, 100% of the lamps are placed under pressure in an aquarium to check for leaks. It doesn’t matter they get wet since they dry quickly during the subsequent durability test. The lamps are laid out on racks and connected to a power supply to confirm they stay lit. You’d see stars after such a test, especially with beacons.

Next, the lamps are packed—first into approved product boxes and then into larger shipping boxes, which are placed onto pallets. When the boxes come off the production line, they are awaited by the quality controller. Random checks are performed on both the lamps and their packaging.

If a product fails inspection, it is examined and repaired by an employee, and the production process is adjusted. There is only one person in the entire factory responsible for this task, as there is almost no rejection.

Development

When a new lamp is developed, it must be certified before it can be sold and used within the European Union. Before such a newly developed lamp goes to the independent testing facility, it undergoes exhaustive testing at the factory.

Being a test lamp isn’t easy! You’re blasted with ultra-fine Arizona dust, placed in an oven for hours where the temperature wildly fluctuates between -40°C and +60°C, then subjected to a high-pressure shower, even with saltwater. As if that weren’t enough, you’re mounted on a vibrating plate that bounces and shakes you in every direction, proving you can stay lit without shock absorbers on a vehicle. In a soundproof room, you get a brief moment of calm as your electromagnetic radiation is measured. Finally, you’re put inside a lightproof chamber to measure your lumens, which must remain consistent.

Not all tests are listed here to keep things readable, but we are convinced that our suppliers go to great lengths to deliver high-quality lighting. And that’s exactly what MobiLED and M-LED stand for.