When to Use Custom Led Pcb?

Author: May

Jul. 07, 2025

Custom LED PCB: Complete Guide to Design, Prototyping, and ...

In the fast-growing electronics and lighting industries, custom LED PCBs are the key to achieving modern custom LED lighting solutions. Whether it is smart homes, automotive headlights, architectural lighting, or wearable devices, the demand for high-performance and custom LED circuit boards is constantly on the rise.

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By using custom LED PCBs, engineers can design suitable LED PCB boards according to project requirements. This helps to enhance brightness, reduce heat, and achieve special shapes or layouts. Whether you need PCB LED light strips, small LED control boards, or high-density SMD LED PCB boards, custom LED services can provide flexible solutions.

This guide will introduce the definition of custom LED PCBs, the design process, the entire process from PCB prototype to mass production, and why working with a trusted custom LED manufacturer like PCBasic is critical to your success.

What is a Custom LED PCB?

Custom LED PCBs are specially designed circuit board LED components for mounting and controlling LED components. Unlike standard circuit boards, custom LED PCBs are designed based on specific project requirements, such as size, heat dissipation capacity, power distribution and so on.

These custom LED boards are not merely carriers of components; they have a direct impact on the brightness, lifespan and overall performance of PCB LED lights. Depending on the different usage scenarios, LED PCB boards can be made of materials such as aluminum substrates (for heat dissipation), FR4 or ceramics.

A standard custom LED PCB mainly consists of the following parts:

•  LED chips or custom LEDs

•  Copper layers for power delivery

•  Insulation layers for electrical isolation

•  Heat sinks or thermal vias

•  Mounting holes or connection terminals

Common types of custom LED PCBs:

•  SMD LED PCB boards

•  PCB LED strips

•  Rigid or flexible LED PCB boards

•  Circular or ring-shaped PCB LED boards

•  Integrated LED control boards

Benefits of Using Custom LED PCBs

Applying custom LED PCBs to lighting projects has the following main advantages:

Customizable Performance

With a custom LED PCB design, the brightness, circuit layout and power parameters can be adjusted as needed to meet the requirements of specific applications.

Efficient Heat Management

A well-structured LED light PCB board is conducive to rapid heat dissipation. Especially the LED PCB board with aluminum substrate can extend the LED lifespan and improve the stability of the system.

Flexible Shape Options

Custom LED PCBs support various shapes. Whether it is a flexible PCB LED strip or a thin circular custom LED board, they can all be designed according to the installation space.

Enhanced Control Functions

After integrating the LED control board, you can manage brightness, color and even connection Internet of Things (IoT) system can be directly achieved through the LED circuit board.

Custom LED PCB Design Process

Designing high-quality custom LED PCBs requires following clear processes based on engineering specifications and best practices.

1. Define Application Requirements

First, determine how many custom LEDs are needed and what type they are. Determine the working voltage, current, expected heat output and heat dissipation method. Meanwhile, confirm the size and mounting conditions of the PCB LED board to match the product structure.

2. Choose the Right Materials

Select the base material based on the thermal requirements and reliability requirements of the project. Aluminum substrates are usually used in high-temperature environments. FR4 is suitable for general applications. Ceramic substrates are suitable for applications with extremely high-reliability requirements.

3. Design Circuit Layout and Routing

Arrange the LED positions reasonably to ensure uniform light output. Use wide copper traces to ensure the power flow efficiency on the LED circuit board. Add thermal through holes and a large copper area to enhance heat dissipation. If the design includes an LED control board, the relevant control circuit should be added.

4. Simulation and Validation

Simulate the thermal distribution and light output using the design tool. Carry out DFM (Design for Manufacturability) checks to avoid production issues and increase the success rate of the first prototype.

5. Prepare Production Files

Generate the required production documents, including Gerber files, BOM (Bill of Materials), and pick-and-place files. These files will be submitted to the custom LED manufacturer to begin the next step.

After completing these steps, you can move into the PCB prototype stage to verify the performance and manufacturability of the design.

About PCBasic

Time is money in your projects – and PCBasic gets it. PCBasic is a PCB assembly company that delivers fast, flawless results every time. Our comprehensive PCB assembly services include expert engineering support at every step, ensuring top quality in every board. As a leading PCB assembly manufacturer, we provide a one-stop solution that streamlines your supply chain. Partner with our advanced PCB prototype factory for quick turnarounds and superior results you can trust.

PCB Prototype to Production: What to Expect

PCB prototyping is a key step in developing a custom LED PCB, and it usually includes the following stages:

1. PCB Prototype Fabrication

At this stage, a small batch of LED PCB boards is produced to test the circuit layout and basic functionality. Engineers focus on checking thermal management, brightness uniformity, and power stability to ensure the design meets expectations.

2. Assembly of Custom LEDs

After the prototype is fabricated, custom LEDs are mounted onto the board. This is typically done using SMT or through-hole assembly. If the design includes control features, LED control board components are also added.

3. Testing

The prototype boards undergo various tests, including electrical testing, thermal testing, and light output evaluation. Engineers also inspect the PCB LED lights for solder quality, component alignment, and overall structural reliability.

4. Scale-Up to Mass Production

If the testing is successful, full-scale manufacturing of the custom LED PCB can begin. Depending on the application, protective coatings or enclosures may also be added.

Whether the production volume is 10 units or 10,000, a well-executed PCB prototype process is critical to ensuring the final custom LED lighting product is stable and reliable.

Applications of Custom LED Circuit Boards

Custom LED PCBs are widely used across many industries. They are especially suitable for applications that require special sizes, shapes, or lighting effects. Common uses include:

● Automotive

Custom LED PCBs are often used in car lighting systems, such as headlights, tail lights, and interior ambient lights. They provide high brightness and a stable power supply.

● Architecture and Interior Design

PCB LED strips and custom-shaped LED circuit boards are used for decorative lighting. They allow flexible light layouts and can fit different space designs.

● Medical Equipment

LED light PCB boards are used in diagnostic and treatment devices. They require stable light with low heat. Aluminum-based custom LED PCBs are ideal for this.

Are you interested in learning more about Custom Led Pcb? Contact us today to secure an expert consultation!

● Consumer Electronics

Custom LED lighting is used in keyboards, wearables, and household appliances. It supports backlighting and status indicators and fits compact circuit structures.

● Advertising and Displays

Custom LED boards are used for even backlighting, complex lighting patterns, and color control. They are common in signs, displays, and outdoor screens.

These applications often need non-standard sizes, special shapes, or advanced control features. Only custom LED PCBs can meet these specific requirements.

Choose PCBasic for Custom LED PCB Manufacturing & Assembly

At PCBasic, we offer complete custom LED PCB solutions—from concept design to mass production. Our technical team and production system can support all types of lighting projects with speed, accuracy, and reliability.

● Full Manufacturing Capability

We handle the entire process, from PCB LED board design to final LED control board assembly. We support fast PCB prototyping, small-batch production, and large-scale orders—from just 1 piece to over 100,000 units.

● Industry-Leading Expert Team

Our PCB design and project management team has over 10 years of experience. We also work with PhD research teams from top universities to develop advanced custom LED lighting technologies, including thermal layout and SMD LED PCB board integration.

● Advanced Equipment and Supporting Systems

PCBasic operates multiple facilities across different locations:

● Shenzhen factory for small-batch production

● Huizhou factory for high-volume automated manufacturing

● In-house stencil and fixture factory

● CNC precision machining workshop

● Central warehouse for electronic components, with guaranteed original parts

We also offer a one-click BOM import and an instant online quoting system to speed up your sourcing process.

● Certifications and Quality Assurance

PCBasic is a certified National High-Tech Enterprise. We are ISO , ISO , IATF , ISO , and UL certified. As an IPC member, we hold over 20 patents related to quality inspection and production management. Every custom LED PCB we produce meets international quality standards.

● Global Delivery and Support

We provide fast PCB prototype delivery. Stencils can ship in as little as one hour. Our global logistics system ensures your custom LED boards are delivered on time and ready for use.

Conclusion

From the initial concept to the final mass production, custom LED PCBs are the foundation of advanced lighting technology. Whether you are designing high-performance LED circuit boards, developing PCB prototypes, or assembling smart LED control boards, choosing the right design process and partners is of vital importance.

With flexible materials, efficient thermal management and unlimited customizability, custom LED lighting is more powerful and achievable than ever before. PCBasic is ready to help you turn your ideas into reality through professional custom LED PCB design, manufacturing and assembly services. Are you ready to start? Contact PCBasic immediately to inquire about your custom LED PCB project or apply for PCB prototyping services.

LED PCB - PCB Prototype the Easy Way - PCBWay

LED stands for Light-Emitting Diode, which is a semiconductor diode. LEDs are soldered onto PCBs and are equipped with a chip that generates light through electrical connections. A heat sink and a ceramic base are used to connect the chip. Undoubtedly, LED PCBs are the core of LED lighting. An LED PCB tends to generate a significant amount of heat, which is challenging to dissipate using traditional methods. Metal core PCBs, especially those made of aluminum, are widely used in LED applications due to their strong heat dissipation capabilities. Typically, an aluminum PCB includes a thin layer of thermally conductive material, which efficiently transfers and dissipates heat compared to traditional rigid PCBs.

Currently, surface mount packaging is the most widely used form of LED packaging in LED applications. Generally, the light emitted by a single LED component is limited. Therefore, a luminaire will utilize multiple LED components to achieve sufficient brightness. Similar to other semiconductor devices, PCBs provide the optimal means of electrical connection for LED components. PCBs with LED components are commonly referred to as "LED PCBs."

Advantages of LED PCB:

When it comes to the advantages of using LED PCB, well there are plenty of them and we are now going to mention a few so that you know about the application too.

  • Lower Power Consumption: Replacing incandescent bulbs with LED lights can reduce power consumption by over 80%.

  • Longer Lifespan: LEDs typically have a lifespan of over 20,000 hours, allowing for continuous usage for up to 3 years, which is 25 times longer than incandescent bulbs. This not only saves costs but also reduces the frequency of replacement.

  • Higher Efficiency: Incandescent bulbs emit a significant amount of heat, while LEDs can reduce it by up to 20%. This means that unnecessary heating can be reduced even when using higher-power LED lights.

  • Smaller Size: Due to their compact size, LED lights can come in various dimensions, making them applicable in different locations. Manufacturers can incorporate LEDs into anything, whether it is electronic devices, automobiles, traffic signals on roads, or signage.

  • Environmentally Friendly: Unlike other types of bulbs, LED lights do not contain mercury. Therefore, LEDs have a smaller environmental impact and are easier to dispose of or handle.

Applications of LED PCB

PCB LED lights offer excellent energy efficiency, low cost, and maximum design flexibility, making them suitable for many lighting applications.

Telecommunications: LED indicator lights and displays are commonly used in telecommunications equipment due to their mechanical compatibility and excellent heat dissipation capabilities. Therefore, aluminum-based LED PCBs play a crucial role in their applications.

Automotive: Aluminum PCB LEDs are also used in automotive indicator lights, brake lights, headlights, and other applications. Several factors make aluminum PCBs ideal in the automotive industry, including durability and competitive pricing.

(Photo by PCBWayer's feedback)

Computers: LED displays and indicator lights are increasingly popular in computer applications. Due to the thermal sensitivity of computer components, aluminum PCB LEDs provide an ideal solution. In addition to LED applications, aluminum PCBs are also used in computer components such as power supplies and CPU boards due to their heat dissipation and transfer capabilities.

Medical: Lighting tools used in surgical procedures and medical examinations often utilize high-power LED lights, typically using aluminum PCBs. This is mainly due to the durability and heat dissipation capabilities of aluminum PCB LEDs, ensuring the proper functioning of medical equipment, regardless of the number of patients cycled through medical facilities. Apart from lighting tools, medical scanning technologies frequently employ aluminum PCBs as well.

General introduction of Aluminum PCB

PCBWay supplied affordable LED PCBs

As a PCB manufacturer with more than a decade of experience, we can provide LED PCB fabrication, components purchasing and assembly. You just need to upload your customized Gerber file and BOM for us to quote. And then you can check our quotation and decide to buy from us or not, it is also acceptable that you supply us the parts for assembly if you want. 

LED Strip PCB:

An LED strip PCB, also known as a printed circuit board, is a specialized circuit board designed for use with LED light strips. LED strips consist of a series of individual light-emitting diodes (LEDs) that are mounted on a flexible or rigid strip of material. The PCB serves as the base or substrate onto which the LEDs are soldered, providing electrical connections and support.

The LED strip PCB typically has copper traces or conductive pathways that connect the LEDs in a specific configuration, allowing for the flow of electrical current to power the individual LEDs. The PCB also provides structural stability and protection for the LEDs, as well as thermal management to dissipate heat generated by the LEDs.

LED strip PCBs come in different forms depending on the type of LED strip. For flexible LED strips, the PCB is usually made of a flexible material like polyimide, which allows the strip to bend and conform to different shapes and surfaces. Rigid LED strips, on the other hand, use a rigid PCB material like fiberglass or aluminum, providing a more stable and durable construction.

LED strip PCBs may also feature additional components such as resistors, capacitors, or integrated circuits (ICs) to regulate voltage, control brightness, or enable various lighting effects. These additional components are often mounted directly onto the PCB.

Overall, LED strip PCBs play a crucial role in providing electrical connectivity, support, and thermal management for LED light strips, allowing for easy installation and integration into various lighting applications.


-120-24V-5mm
k/k/k/k/k

The parameters you mentioned for an LED strip PCB are as follows:

  1. Lumens: Lumens is a unit of measurement that indicates the total amount of visible light emitted by an LED strip. It represents the brightness of the LED strip. The exact lumen output of an LED strip can vary depending on the specific model or configuration.

  2. : refers to the size and type of LED chip used in the LED strip. The number represents the dimensions of the LED chip, which is 2.8mm by 3.5mm. It is a commonly used size for LED chips in LED strips.

  3. 120: The number 120 usually refers to the number of LEDs per meter or per unit length of the LED strip. In this case, it indicates that there are 120 LEDs present in every meter or per unit length of the LED strip.

  4. 24V: The voltage rating of the LED strip indicates the level of electrical voltage required to power the LEDs. In this case, the LED strip operates at 24 volts. It is important to ensure that the power supply used for the LED strip matches the voltage requirement to avoid damaging the LEDs.

  5. k: The color temperature of an LED strip is measured in Kelvin (K) and indicates the color appearance or "warmth" of the light emitted. In this case, the LED strip has a color temperature of Kelvin, which represents a warm, yellowish-white light similar to traditional incandescent bulbs.

  6. 5mm: The parameter "5mm" typically refers to the width or diameter of the LED strip. It indicates the physical size of the strip. However, it's worth noting that most LED strips are available in various width options, commonly ranging from 8mm to 12mm. The width can affect the flexibility, intensity, and heat dissipation capabilities of the LED strip.

These parameters provide specific information about the characteristics and specifications of the LED strip PCB, such as brightness, LED chip size, LED density, voltage requirement, color temperature, and the width of the strip.

For more Smdinformation, please contact us. We will provide professional answers.

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