The production process of LED displays is quite complex, with each step being crucial to ensuring the quality and performance of the final product. Below is a detailed explanation of each stage in the production process:

1. LED Chip Selection

Overview: The LED chip is the core component of an LED display, determining key parameters like brightness, color performance, contrast, and lifespan. The quality of the chip directly affects the overall performance of the display.

Chip Types: Common types include SMD (Surface Mounted Device) and COB (Chip on Board). SMD LEDs are used for most indoor and outdoor displays, while COB LEDs have better waterproof and impact-resistant properties.

Key Parameters:

-  Wavelength Consistency: Ensures color consistency across the display.
-  Brightness: Affects the visibility of the display, especially under strong outdoor lighting.
-  Lifespan: High-quality LED chips can last over 100,000 hours.

2. PCB Board Manufacturing

Overview: The PCB (Printed Circuit Board) is the foundation of the LED display, carrying the LED chips and other electronic components. A well-designed circuit ensures stable signal transmission and electrical current.

Manufacturing Process:

-  Circuit Design: Design the circuit according to the functionality requirements, including power and signal transmission circuits.
-  PCB Fabrication: Produce the PCB through processes like drilling, plating, and etching to ensure durability and conductivity.
-  Component Mounting: Using a surface-mount machine, solder LED chips and other components (such as driver ICs) onto the PCB.

3. LED Module Assembly

Overview: LED modules are the building blocks of LED displays, consisting of multiple LED pixel units, with each pixel containing red, green, and blue LEDs.

Process:
-  LED Soldering: LED chips and driver ICs are soldered onto the PCB using SMT (Surface Mount Technology).
-  Enclosure Assembly: Install the LED units into the module housing for physical protection and heat management.
-  Cable and Signal Line Connection: Connect power cables and signal lines to ensure that each module can transmit signals synchronously.

4. Module Testing

Overview: After assembly, the module undergoes a series of tests to ensure that it meets performance and quality standards.

Testing Items:
-  Brightness Test: Ensures that each LED chip achieves the required brightness.
-  Color Consistency Test: Checks that the color is uniform across the module, avoiding discrepancies.
-  Electrical Test: Tests parameters such as voltage and current to ensure compliance with standards.
-  Functional Test: Ensures that the module operates correctly, including signal transmission and image display.

5. Display Screen Assembly

Overview: This stage involves assembling multiple LED modules onto the display frame based on the design's size and layout.

Process:
-  Module Installation: Install the tested modules into aluminum or steel frames, ensuring seamless alignment between modules.
-  Module Splicing: Combine multiple modules into a complete display unit according to the display’s size and shape.
-  Structure Reinforcement: Reinforce the frame to prevent deformation during transportation or use.

6. Power and Control System Installation

Overview: The power supply and control system are the "heart" of the LED display, providing stable power and ensuring that the image signals are transmitted and displayed correctly.

Power System:
-  Power Module Selection: Choose the appropriate power modules based on the display's power consumption to ensure stable voltage and current.
-  Power Layout: Arrange the power modules to prevent heat concentration and ensure proper heat dissipation.

Control System:
-  Sending and Receiving Cards: The sending card transfers image signals from a computer to the receiving card, which then distributes the signals to each module.
-  Signal Cable Connection: Ensure that signal lines are connected properly to avoid signal loss or delays.

7. Display Calibration

Overview: After assembly, the entire LED display requires color and brightness calibration to ensure consistent visual performance.

Calibration Methods:
-  Software Calibration: Adjust brightness and color through control software to ensure uniform display across different modules.
-  Optical Calibration: Use colorimeters and luminometers to test and adjust the entire display, ensuring accurate colors and uniform brightness.

8. Aging Test

Overview: The aging test involves running the LED display for an extended period to simulate real-world conditions and test its stability and durability.

Testing Content:
-  High-Temperature Test: Run the display at high temperatures to check for any degradation in electrical or optical performance.
-  Long-Time Operation: Keep the screen continuously lit for several hours or days to detect brightness decay or flickering issues.
-  Humidity Test: Simulate humid environments to ensure the display can function properly under adverse conditions.

9. Final Product Testing

Overview: After the aging test, the entire display undergoes final product testing to ensure that it meets customer requirements and industry standards.

Testing Items:
-  Brightness Test: Ensure uniform brightness across the display, meeting design standards.
-  Color Test: Check the color reproduction across the display, ensuring no color distortions.
-  Refresh Rate Test: Ensure that the display's refresh rate meets the required standards, avoiding flickering or image tearing.
-  Viewing Angle Test: Test the display’s performance from different angles to ensure clear and consistent images from wide viewing angles.

10. Packaging and Transportation

Overview: After passing the final tests, the LED display is carefully packaged to prevent damage during transport.
Packaging Methods:

-  Shockproof Packaging: Use foam, bubble wrap, and other materials to protect the display from vibrations and shocks during transportation.
-  Dust and Moisture Protection: Add desiccants and seal the packaging to prevent moisture damage.
Transportation: Choose the appropriate transportation method, such as land or air freight, to ensure the safe delivery of the display.

Each stage of the LED display production process is carefully managed and controlled to ensure high performance and long lifespan for the final product.

 Mepro LED was founded in 2019, primarily engaged in the ODM/OEM production and application of LED displays. The company has a production and operation area of 8,000 square meters and an average monthly production capacity of 7,000 square meters. It is equipped with advanced facilities, including an AI comprehensive automatic DIP line, fully automatic SMT production line, energy-saving automatic soldering line, fully automatic glue filling line, finished product assembly line, post-welding line, and module/finished product aging line. 

As a highly professional LED display manufacturer, we look forward to working with you.