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LED High Bay PCB Assembly--STHL

LED High Bay PCB is a specialized circuit board designed for high bay LED fixtures, engineered for demanding industrial and commercial lighting applications such as warehouses, factories, and gymnasiums. It adopts advanced aluminum substrate construction with optimized thermal pathways for efficient heat dissipation, supporting high-wattage LED arrays (100W to 500W) while maintaining compact form factor. Think of it as the "core driver" of high bay lights, responsible for stable power supply and uniform light distribution, with industrial-grade durability to withstand vibration, temperature fluctuations, and moisture. Our 2 DIP production lines and strict quality testing ensure each PCB meets industrial lighting standards, with high power density and low power loss.

LED High Bay PCB Assembly--STHL

Early challenges in LED High Bay adoption—such as insufficient high-power load capacity, electromagnetic interference (EMI), and inadequate thermal management for large-space illumination—have been overcome by specialized PCB assembly technologies, particularly rigid PCBs and high-precision surface mount technology (SMT). These innovations effectively enhance the stability of LED drive circuits for high-wattage operation, while integrating EMI shielding layers to eliminate interference from external industrial equipment and power systems. Rigid PCBs, in particular, balance compact form factors with reliable signal transmission and efficient heat dissipation, supporting the high-power density and modular layout of LED high bay lights without compromising illumination uniformity. This technological leap has enabled LED High Bay PCB Assemblies to outperform traditional high bay light circuits in key areas:

Superior Signal Integrity

Advanced impedance-controlled routing and ultra-low-noise PCB substrates (aluminum core, FR-4, or ceramic options) minimize signal attenuation during the transmission of high-power LED drive signals. Equipped with high-resolution (≥16-bit) ADC integration, they ensure the accuracy of brightness control and stable current output for high-wattage LED arrays (100W to 500W), laying the foundation for uniform light distribution and consistent illumination across large industrial and commercial spaces. This eliminates signal crosstalk and voltage drop, ensuring each LED chip receives stable, accurate drive signals, maintaining consistent light output even under high-power operation.
Versatile Form Factor Adaptability

Compliant with IEC 60598 lighting safety standards (including IEC 60598-1 and IEC 60598-2-1 for fixed industrial lights) and industrial electrical safety specifications, the assemblies adopt reinforced isolation designs (such as double-layer insulation, anti-short circuit protection, and surge protection) to prevent electrical leakage and overload risks. High-quality aluminum-core and FR-4 substrates are used to adapt to diverse high bay light types and power configurations—from compact indoor high bays to rugged outdoor units—supporting flexible modular assembly and seamless integration with industrial control systems. The conformal coating materials also ensure compatibility with various installation environments, whether warehouses, factories, or large commercial spaces with mounting heights of 15-50 feet.
Reliable Long-Term Operation

ENIG (Electroless Nickel Immersion Gold) surface finishes and waterproof conformal coatings (IP67 rating) provide excellent corrosion resistance, moisture protection, and chemical resistance, essential for high bay PCBs exposed to harsh industrial environments. Combined with rigorous temperature (-40°C to +85°C) and vibration testing, as well as enhanced thermal management through optimized thermal pathways and heat-dissipating substrates (thermal conductivity up to 3.0 W/mK), the assemblies maintain stable performance during long-term continuous operation, even under high-power LED drive loads, while complying with electrical safety requirements of dielectric strength > 3000V and supporting sustained operation in demanding industrial settings.

Key Applications Across LED High Bay Sectors

LED High Bay PCB technology powers high-performance, high-wattage illumination solutions in diverse industrial, commercial, and large-space scenarios, supporting efficient, uniform lighting for high-ceiling environments while ensuring long-term reliability.

Industrial Warehouses & Manufacturing Facilities

High-power LED high bay PCB modules, featuring stable high-wattage output and efficient heat dissipation, integrated with industrial control systems for easy operation. These are widely used in warehouses, factories, and manufacturing plants, providing uniform, bright illumination to cover large areas, enhancing operational safety and productivity.

Sports Facilities & Gymnasiums

In stadiums, gymnasiums, and indoor sports centers, the PCB assemblies power LED high bay lights that provide high-brightness, flicker-free illumination. The stable signal transmission and anti-interference design ensure consistent light output, meeting the strict illumination requirements for sports competitions and training sessions.

Commercial & Retail Spaces

Rugged LED high bay PCB assemblies, built with anti-interference circuits and durable substrates, ensure stable performance in large commercial spaces such as hypermarkets, logistics centers, and exhibition halls. They support high-brightness illumination with uniform light distribution, improving visibility and enhancing the shopping or working experience.

Outdoor Industrial & Logistics Yards

Weather-resistant LED high bay PCB modules, leveraging waterproof and corrosion-resistant designs, provide reliable technical support for outdoor industrial yards, logistics terminals, and loading docks. They maintain stable performance in harsh outdoor conditions, including temperature fluctuations and moisture, ensuring safe and efficient operations during day and night.

Why STHL PCBA should be your top choice for your LED PCBA needs?

Let's explore the top 10 reasons why!

Real Factory

STHL PCBA is a real factory with 10,000+m² highly automated, dust-free factory，7 SMT lines, 2 DIP lines, 2 FCT lines, and 2 box building assembly lines.

Quality Guarantee

We buy components from famous international platform like Mouser, Digikey, Farnell, Future, Avnet, Arrow or the agents. No components substitutes without customers approval!

Rich Experience

20+ years of experience in PCB & PCBA field.

Cost Dowm

Professional engineering team supports cost down.

Global Sourcing

500k parts with 100+ agents and suppliers.

No MOQ

No minimum order requests, we accept both prototype and volume quantity orders.

Fully Certified

With IATF16949, ISO9001, ISO14001, ISO13485 Certifications.

NDA

We ensure all of your projects documents security and sign NDA before RFQ.

Intelligent Management

Use Intelligent ERP system, MES (manufacturing execution system) for fast tracking.

Fast Delivery

Prototype orders will be fast completed and delivered, mass orders lead time is 4~5 weeks.

About STHL PCB & PCBA

LED PCB Assembly Revolutionizing Lighting Technology with Precision and Per (1)

Shenzhen STHL Technology Co., Ltd. is a high-quality provider of electronics manufacturing services (EMS) in China, we serve customers worldwide along the whole industry chain including product design, material sourcing, PCBA production, cable assembly, box build assembly and comprehensive testing services.

Established in 2006, we have more than 20 years of experience in electronics contract assembly manufacturing. Currently, we employ more than 220 staff members. Our 10,000 sqm facilities include 7 surface-mount technology (SMT) production lines, 2 through hole technology (THT) lines , 2 function testing lines and 2 box build production lines.

At STHL, we provide electronics assembly services for energy power, communications, consumer electronics, computers & storage, safety & security, commercial and industrial products. Customers mainly from United States, Brazil, United Kingdom, Germany, Spain, Italy, Poland and . As an IATF16949，ISO9001, ISO14001, and ISO13485 certificated electronics assembly manufacturer, we produce products exactly comply with ROHS standard and quality guarantee. Based on our excellent engineering and production capacities in technical areas such as materials analysis & storage, advanced equipment, reliability testing (AOI, X-RAY, ICT test and function test), high effective SMT and THT assembly, we are recognized as a long-term reliable PCBA vendor by more and more customers wordlwide.

Products Capability

Items	PCB capacity
PCB name	LED PCB Assembly: Revolutionizing Lighting Technology with Precision and Performance
Material	FR-4; High TG FR-4; Aluminum; CEM-1; CEM-3; Rogers, etc
PCB type	Rigid, flexible, rigid-flexible
Layer NO.	1, 2, 4, 6, up to 24 layer
Shape	Rectangular, round, slots, cutouts, complex, irregular
Max PCB dimensions	1200mm*600mm
Board Thickness	0.2mm-4mm
Thickness Tolerance	±10%
Min Hole Size	0.1mm (4 mil)
Copper Thickness	0.5 OZ-3OZ (18 um-385 um)
Copper Plating hole	18um-30um
Min Trace Width	0.075mm (3mil)
Min Space Width	0.1mm (4 mil)
Surface finish	HASL, LF HASL, Imm Gold, Imm Silver, OSP etc
Solder mask	Green, red, white, yellow, blue, black, orange, purple
Assembly details	SMT and Thru-hole, ISO SMT and DIP lines
Testing on products	Testing jig/mold , X-ray Inspection, AOI Test, Functional test
Quantity	Min quantity : 1pcs. Prototype, small order, mass order, all OK

Products Capability

Files needed	PCB : Gerber files(CAM, PCB, PCBDOC)
	Components : Bill of Materials(BOM list)
	Assembly : Pick-N-Place file
PCB Panel Size	Min size : 0.250.25 inches(66mm)
PCB Panel Size	Max size : 1200*600mm
Components details	Passive Down to 0201 size
	BGA and VFBGA
	Leadless Chip Carriers/CSP
	Double-sided SMT Assembly
	Fine BGA Pitch to 0.2mm(8mil)
	BGA Repair and Reball
	Part Removal and Replacement
Component package	Cut Tape, Tube, Reels, Loose Parts
PCB+ assembly process	Drilling---Exposure---Plating---Etaching & Stripping---Punching---Electrical Testing---SMT---Wave
PCB+ assembly process	Soldering---Assembling---ICT---Function Testing---Temperature & Humidity

Digital Innovation

Digital Innovation

Digital Innovation

Digital Innovation

Digital Innovation

How to Get Started with STHL

Ready to partner with us for your LED PCB Assembly project? Here’s how you can get started

Contact Us

Reach out to our sales team via phone, email, or online chat to discuss your project requirements.
Provide Design Files

Send us your PCB design files (Gerber, BOM, etc.) for a detailed quote.
Get a Quote

We will provide you with a comprehensive quote, outlining all costs and timelines.
Production and Delivery

Once the quote is approved, our team will begin production, ensuring your PCB assembly is completed on time and to the highest quality standards.

Make an free consultant

Whether you need PCB Fabrication or PCBA Assembly Service, STHL delivers innovation and reliability.

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LED High Bay PCB Assembly--STHL

LED High Bay PCB Assembly--STHL

Superior Signal Integrity

Versatile Form Factor Adaptability

Reliable Long-Term Operation

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Key Applications Across LED High Bay Sectors

Industrial Warehouses & Manufacturing Facilities

Sports Facilities & Gymnasiums

Commercial & Retail Spaces

Outdoor Industrial & Logistics Yards

Why STHL PCBA should be your top choice for your LED PCBA needs?

Real Factory

Quality Guarantee

Rich Experience

Cost Dowm

Global Sourcing

No MOQ

Fully Certified

NDA

Intelligent Management

Fast Delivery

About STHL PCB & PCBA

Products Capability

Products Capability

Digital Innovation

Digital Innovation

Digital Innovation

Digital Innovation

Digital Innovation

Digital Innovation

How to Get Started with STHL

Contact Us

Provide Design Files

Get a Quote

Production and Delivery

Make an free consultant