Why Choose Consons’s LED PCB?
- Efficient Heat Transfer: We provide heavy copper options up to 6 oz (extreme custom copper up to 60 oz for power integration), offering exceptional heat dissipation, making the PCBs suitable for high-power LED modules such as outdoor lighting and stage lighting.
- Oversized PCB Production: We support large-size PCBs with lengths up to 1,200 mm. This reduces the need for connectors, making them ideal for seamless industrial lighting and large-area lighting applications.
- White Solder Mask: We use a white solder mask to enhance light reflection and increase brightness. If you have specific requirements, we can also provide solder masks in other colors.
- Free DFM Review: We provide DFM service to optimize PCB and enclosure compatibility in advance, resolve assembly interference issues, and eliminate the need for rework during mass production.
What Is an LED PCB?
LEDs are 80% more energy-efficient than traditional incandescent bulbs, have a longer lifespan, and are environmentally friendly, making them widely used across various industries. PCBs are used to connect, secure, and control LED components, while also providing stable current delivery and effective thermal management.
Consons offers LED PCBs in a variety of substrate materials and specifications to suit different applications. We also provide OEM/ODM services, offering you a one-stop LED PCB solution. You can send us your Gerber files, and we will provide you with a competitive quote.
LED PCBs Classified by Base Material
Features a lightweight aluminum substrate with good thermal conductivity and cost-effectiveness, widely used in LED lighting, street lamps, and high-power illumination products.
Copper substrate provides superior heat dissipation and electrical performance, supporting high-power LED modules, automotive lighting, industrial lighting, and applications requiring enhanced thermal management.
Built with fiberglass, offering reliable insulation, mechanical strength, and the flexibility for circuit designs. Suitable for low- to medium-power LEDs, such as indicators.
Provides outstanding thermal conductivity, high temperature resistance, and excellent electrical insulation, making it ideal for extreme industrial or aerospace environments.
LED PCBs Classified by Application
Designed for flexible or rigid LED strips, enabling continuous lighting layouts with compact structures. Often used in decorative lighting and commercial illumination projects.
Featuring large-format LED light PCB boards, ensuring broad and uniform brightness. Suitable for office lighting, commercial spaces, and indoor lighting systems.
Engineered for high-output LED components with enhanced thermal performance and current handling capability. Applied in outdoor lighting, stage lighting, automotive lamps, and industrial illumination.
Designed for LED backlight modules, providing precise circuit control, thin thickness, and consistent light distribution. Commonly used in LCDs, monitors, TVs, and electronic display devices.
Reliable Heat Dissipation Performance
Consons carefully plans the circuit layout. We distribute heat sources such as LED chips, driver ICs, and power components in a dispersed layout to minimize hot spots and ensure a more uniform temperature across the entire LED PCB. We have also added thermal vias to allow heat to transfer more quickly from the top to the bottom, improving heat dissipation. The shortened and widened high-current traces further reduce trace impedance and minimize heat generation. This helps ensure stable LED operation and extends the LEDs’ lifespan.
Integrated PCB Assembly Services
We provide integrated LED PCB assembly solutions covering component sourcing, SMT, THT assembly, and functional testing. Our manufacturing capabilities support rigid PCBs, flexible PCBs, and complex board designs with multilayer structures, HDI, heavy copper, and high-frequency materials. Equipped with 15 fully automated SMT lines and comprehensive inspection systems, we achieve surface-mount placement tolerances as tight as ±0.025 mm. From rapid prototypes to large-scale manufacturing, we help customers streamline production processes and achieve reliable PCBA solutions for various electronic applications.
Why Consons Is Your Top Choice?
Consons’ headquarters facility spans 35,000 square meters and has separate production zones, with a total workforce of approximately 1,600 employees. We process 4.5 billion SMT placements per month, equivalent to 10 million PCBA circuit boards. We are capable of reliably handling your high-volume orders.
With 20 years of experience in PCB R&D and manufacturing, we partner with leading global brands across consumer electronics, automotive, industrial control, and smart home sectors. Thanks to our professional service and consistent product quality, Consons’ LED PCBs are sold in Europe, the Americas, Australia, Southeast Asia, and other regions.
Specifications
| Parameter | Specification |
| Product Type | LED PCB / LED PCBA / LED Module PCB |
| PCB Type | Rigid PCB / Flexible PCB / Rigid-Flex PCB |
| Base Material | Aluminum PCB / Copper Core PCB / FR-4 PCB / High TG FR-4 / Ceramic PCB |
| PCB Layers | 1–30 Layers (Rigid PCB), 1–8 Layers (FPC) |
| Copper Thickness | Standard: 1/3 oz–2 oz; Heavy Copper: Up to 60 oz |
| Board Thickness | 0.1–3.2 mm (Typical); Customized thickness available |
| Minimum Line Width/Spacing | Down to 3.5/4 mil for rigid PCB; 2 mil for FPC |
| Minimum Drilling Size | Mechanical drilling ≥0.15 mm; Laser drilling down to 4 mil |
| Surface Finish | ENIG, OSP, HASL Lead-Free, Immersion Tin, Immersion Silver, Gold Finger |
| Thermal Management | Aluminum Core, Copper Core, Ceramic Substrate, Thermal Via Design |
| Thermal Conductivity | Customized thermal solutions available; high-performance materials can exceed 20 W/mK |
| PCB Structure | Single-sided / Double-sided / Multilayer PCB |
| Special PCB Capability | HDI PCB, Heavy Copper PCB, High Frequency PCB, Impedance Control PCB |
| Solder Mask Color | Green / Black / White / Customized |
| Application | LED Lighting, LED Strip, LED Panel, High Brightness LED, Backlight Unit, Automotive Lighting |
| LED Assembly Capability | SMT Assembly / THT Assembly / Mixed Technology Assembly |
| Component Placement Capability | Supports 01005 components, BGA, QFP, and other fine-pitch components |
| Assembly Accuracy | Placement tolerance down to ±0.025 mm |
| Inspection Methods | AOI Inspection, X-Ray Inspection, ICT Testing, Functional Testing |
| Production Capacity | Rigid PCB: up to 100,000㎡/month; FPC: up to 50,000㎡/month |
| SMT Production Capacity | Up to 4.5 billion placement points/month |
| Prototype Service | Rapid Prototyping and Small-Batch Production Support |
Project Case of Consons LED PCB
The client needed an outdoor LED system with ultra-high brightness, precise RGBW color consistency, and thermal stability under high currents.
Consons uses RGBW LEDs, which can produce rich and accurate colors. We reduce unnecessary current paths, lowering power loss and improving electrical efficiency. The enlarged copper areas around high-current LED channels improve current distribution and enhance heat dissipation efficiency. This maintains consistent brightness output across the lighting system and helps extend the lifespan.
This customer required an extra-long LED PCB board for linear lighting fixtures. However, the long current path may cause voltage drops, making it difficult to maintain uniform brightness.
We selected high-Tg FR-4 materials with improved thermal stability to minimize dimensional changes during high-temperature processing. At the same time, the dual-end power input effectively resolved the issue of uneven brightness caused by voltage fluctuations. Finally, this 1,500-mm-long LED PCB module received high praise from the customer.
You Can Use Our LED Light PCB for:
Our RGBW/RGB LED PCB provides vibrant lighting solutions for smart home lamps, decorative lights, LED strips, and commercial signage. Supporting red, green, blue, and dynamic color effects, it delivers flexible lighting control, uniform illumination, and reliable performance for creative display applications.
Designed for communication equipment such as router indicators, server status lights, and network control panels. Our LED PCB boards provide compact layouts, stable signal indication, and dependable operation in systems requiring continuous monitoring and high reliability.
The strong thermal resistance, vibration tolerance, and reliable performance make LED PCBs meet demanding automotive environments. They are an excellent choice for vehicle lighting applications. Including headlights, taillights, dashboard indicators, and interior ambient lights.
Applied in medical devices such as diagnostic equipment indicators, display backlights, surgical lights, and instrument control panels. LED light PCB ensures accurate illumination, stable operation, and long-term reliability for healthcare equipment requiring precise visual feedback and continuous lighting performance.
More Products
Integrates power management circuits to ensure efficient energy conversion and safe charging performance. Widely used in mobile chargers, power adapters, wireless chargers, and electronic power devices.
Supports precise sensor integration with reliable signal processing and circuit control. Suitable for smart devices, industrial equipment, IoT systems, and environmental monitoring applications.
Consons provides comprehensive document management and confidentiality procedures to protect your intellectual property. This includes signing non-disclosure agreements (NDAs), restricting access to design files, Gerber files, bills of materials (BOMs), and other materials, and controlling document flow through internal access management. We ensure that your proprietary designs are not copied without authorization or used in other projects. For production processes involving confidential information, we strictly control electronic devices used by on‑site operators to avoid sensitive‑information leaks.
Whether a flexible LED PCB is suitable for high-temperature environments depends primarily on the substrate, coverlay, adhesive, and overall structural design. Standard flexible PCBs typically use polyimide (PI) material, which offers good heat resistance and can withstand temperatures up to 150°C. However, the long-term operating temperature ranges vary depending on the material grade. For high-temperature applications, you should select high-temperature-resistant PI materials, optimize the heat dissipation design, and also consider the actual operating temperature, power density, and environmental conditions.
First, you need to confirm whether the supplier can provide substrate materials suitable for LED applications, such as aluminum PCBs, copper-core PCBs, high-thermal-conductivity FR-4, or ceramic PCBs. Second, you should focus on their PCB manufacturing and assembly capabilities, including the range of layer counts, copper thickness capabilities, SMT assembly, and inspection processes. Lead times are also critical. Consons offers a one-stop turnkey service, with express prototyping shipped within 24 hours, small-batch orders fulfilled in 2–3 days, and standard mass production completed in 3–7 business days.
Standard LED PCBs typically use a copper thickness of 1 oz to 2 oz(about 35 μm to 70 μm), which is suitable for most general LED applications. For high-power LED modules, industrial lighting, or high-current applications, consider increasing the copper thickness up to 3 oz, 5 oz, or even thicker designs (heavy copper PCBs). This reduces resistive losses and improves current-carrying capacity. Additionally, the thermal conductivity of the substrate, the PCB structure, and the thermal design all influence heat dissipation performance.
LED PCB layout requires a comprehensive consideration of current transmission, thermal management, and optical performance. The placement of LED components and heat-generating components should be carefully planned to avoid heat concentration and form hot spots. You should design appropriate trace widths and copper areas based on current requirements to reduce the additional heat generated by resistance. For high-power LED applications, it is necessary to consider thermal vias, heat spreading areas, and the heat transfer paths between the LEDs and the heat sink. Furthermore, the spacing and arrangement of LEDs also affect light uniformity.
The main difference between an LED PCB and an LED PCB module lies in the level of product completion. An LED PCB refers to a printed circuit board used to mount LED components. It primarily consists of a substrate, copper circuit, pads, and a thermal structure. It typically does not include LED chips, and you must perform the mounting and assembly at a later stage. An LED PCB module is a fully assembled module based on the LED PCB. It typically includes electronic components such as LED chips, resistors, capacitors, and driver ICs. LED PCB modules can usually be used directly in lighting products.