How a Free Tear-Down Analysis Can Improve Your LED Assemblies and Save You Time and Money

    October 1, 2015

You don’t know what you don’t know.

But you can discover what you don’t know and improve the quality and cost-efficiency of your LED assembly process with a free LED lighting assembly tear-down analysis.

At Henkel, we’re more than just the world’s leading adhesive and sealant producer. We’re also experts. We’re a team of experienced engineers with the knowledge to help you improve your assemblies. Our tear-down analysis has provided benefits to customers in many industries over the last 10 years.

Our service includes a detailed tear-down of your product and a step-by-step analysis of where current techniques and materials could be made better, faster, higher quality and/or less expensive through the use of quality LED-compatible adhesives, sealants and surface treatments. 

A sampling of recent tear-down analysis results included such recommendations as:   

  • The assembly’s thermal performance can be improved with high-performance potting, thermal interface material (TIM) and by sealing joints with adhesive.

  • High-strength acrylics and epoxies can be used to unitize bond lines and reduce reliance on threaded fasteners, clips and rivets.

  • By eliminating cut gaskets in favor of anaerobic and silicone liquid gaskets, you can eliminate inventory, more easily adapt to new designs and provide the value-added customer benefit of a permanently placed gasket.

  • You can improve metal surface finishes, weather resistance and paintability by using surface treatment products.

  • You can increase manufacturing throughput by simplifying designs and replacing older ambient or heat-curing materials with modern instant-curing adhesives and sealants.    

How Does Our Free Tear-Down Analysis Work?

We begin the process by examining a fully functioning unit in its original packaging from the manufacturer’s production site. We also examine drawings, schematics and manuals for the product. Documentation on the current manufacturing process, layout and workflow with a special focus on challenges, bottlenecks and cost-drivers is also very important.

Our engineers and technicians then disassemble the unit, first into subassemblies, and then down to the component and even sub-component level. The results of the analysis are compiled in a standardized, illustrated report (25-100 pages is typical) that details all findings and recommendations, prioritized based on the potential benefit to the customer. Photographs, test results, diagrams, findings and a preliminary benefit assessment are all part of the report.

The tear-down analysis concludes with a recommended action plan based on specific testing and production process recommendations, listing the steps that may be taken to quantify and qualify the benefits. 

Typical Results

Manufacturers that take action based on our recommendations typically see improved assemblies, cost savings and faster production times. If you’re interested in a free report, we’d love to hear from you. Get in touch.

About the Author, Matt Donelan

Matt Donelan is a Market Development Director for Henkel North America based in Rocky Hill, Conn. His responsibilities cover the Electrical and Optical segments including Lighting, Wire Harnesses, and Electric Motors. Matt has over 20 years of experience at Henkel in both marketing and product management positions. He also has design, test, and manufacturing engineering experience in the aerospace, optical, medical and electronics industries. Matt holds a bachelor's degree in mechanical engineering from The University of Connecticut and an MBA from the University of Hartford.

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