Measurement Sensors for the LED Industry

The LED industry has entered a stage in which 0603 LEDs are considered giant, despite the fact they’re only 1.6 mm × 0.8 mm in size. LEDs have become so small that their components are 10x to 100x smaller than previous models.

Manufacturing these new LEDs requires extreme miniaturization. Traditional measurement methods are becoming less viable, as many can’t accurately measure such small components. As a result, manufacturers are turning towards non-contact measurement sensors — such as laser profilers and laser displacement sensors — as precise, non-invasive replacements.

Key Features of Laser Measurement Tools for LED Analysis

The ongoing miniaturization efforts to reduce the scale of LED chips and packages while maintaining their effectiveness has made laser measurement tools indispensable within the LED industry, thanks to their high accuracy and fast scanning speeds.

Here are some of the most important features associated with LED measurement systems for LED analysis:

Highly Accurate 3D Measurements

The need for precision in the LED industry, particularly with the emergence of mini- and micro-LEDs, can’t be overstated—particularly because light-emitting diodes are everywhere now, from general lighting applications to advanced electronics. The latter often imposes stringent specifications, which underscores the importance of highly accurate 3D measurements in the LED industry.

KEYENCE’s WI-5000 Series 3D interference LED measurement sensor exemplifies the capabilities required for such applications, enabling batch in-plane measurements on the same axis with the minimum measuring pitch of 4µm. This allows for extremely accurate 3D measurements and surface scanning of LED and PCB components with very high precision.

Fast Response Time and Real-Time Monitoring

LED manufacturing (especially on the mini and micro scales) has taken the shape of CPU production, pointing towards a speedy production process. Fortunately, on top of their accuracy, KEYENCE’s WI-5000 Series provides very fast response times, allowing real-time monitoring of production processes.

This enables manufacturers to monitor the production process and make necessary adjustments to the process to maintain product quality. The ability to quickly measure and analyze mini- and micro-LED components as they’re being manufactured significantly reduces the risk of defects, ensuring that the production process remains effective.

Compatibility with Different LED Types and Configurations

The LED industry encompasses a wide range of LED types and packages, each with its own specific use case and performance criteria. The importance of precise LED measurements in this industry is further underscored by the introduction of high-definition screen displays based on mini- and micro-LED technologies, which rely on sub-mm packaging and configurations.

LED sensors offer exceptionally high precision, often measured in the single-digit µm range, making these sensors highly versatile and capable of scanning various LED types and configurations. Furthermore, their high precision offers increased adaptability to even smaller packages, which is crucial for reliable implementations in an industry where miniaturization is one of the key drivers of success.

Manufacturers can now use a single LED sensor type to measure different LED productions ranging from micro-LEDs present in screen displays to small indicator lights and large lighting panels.

Laser Measurement Tools

Laser measurement sensors for the LED industry bring a whole new level of precision, speed, and versatility perfectly suited for the ongoing miniaturization of electronic components. LED sensors are great at providing highly accurate 2D and 3D measurements, ensuring that the products meet strict quality standards.

As the LED industry continues to grow and the technology continues to evolve, the role of LED sensors and LED measurement systems in precise measurements will become even more pronounced.

If you’re looking to implement laser measurement and LED sensors into your existing manufacturing process, don’t hesitate to contact KEYENCE and inquire with our team about possible integrations with your current system.