Disappointing trend in LED manufacturing

[desert.snake]

Virtually none. The headlight would have a large interdisciplinary team of optics engineers, mechanical engineers, and EEs, as well as manufacturing specialists. Every aspect of it will have been simulated before a tool was every cut. After tooling and extensive design validation testing, extensive testing for abnormal conditions and extensive accelerated life testing would occur. Then, and only then will it get to the consumer. Things slips by in design, as no test has 100% coverage, but your post is pure fantasy. Your friend and you obviously have absolutely no experience with automotive design, and I expect you have little experience with lifetime prediction of LED assemblies for automotive.

I've been working on some things for a while, where testing and development is much more rigorous and extensive than some small, middle-class car. Theory, tests and practice are two different things. . Despite what you have listed, cars still break down, their headlights burn out ahead of time, and their bodies crumble to dust due to rust. And mind you, I didn't talk about other aspect of headlight design other than terrible bad heat dissipation.

Yes, the body really rots very quickly. The salt on the roads and the climate are taking their toll. 2-4 years and through rust may appear in the body

 

[JustAnOldFashionedLEDGuy]

I've been working on some things for a while, where testing and development is much more rigorous and extensive than some small, middle-class car. Theory, tests and practice are two different things. . Despite what you have listed, cars still break down, their headlights burn out ahead of time, and their bodies crumble to dust due to rust. And mind you, I didn't talk about other aspect of headlight design other than terrible bad heat dissipation.

Yes, the body really rots very quickly. The salt on the roads and the climate are taking their toll. 2-4 years and through rust may appear in the body

Unless you are doing military or space, or infrastructure telecom, your design and testing is likely not nearly at the level of a small middle class car that has much more extensive and complete design and test that a low volume ultra high end car. The costs of high failure rates for cars is astronomical and hence avoided. You are showing you don't understand the process at all. Cars do breakdown, but less and less every year and I checked and no reports of unusual failure rates for Camry headlights.

I have not seen any car rust through in 2-4 years in 3+ decades and I practically drive in a salt spray 4+ months of the year where it is cold enough that salt is used all the time, but warm enough to have liquid/corrosion at near optimal rates. I put 30,000+ miles/year on cars for decades and never had perforation in < 7 years. With the galvanation processes, and multi-step painting processes, even on cheap cars, it just does not happen any more, hence 5+ year unlimited mileage perforation warranties. You may get the odd process failure but exceedingly rare. You see a car with perforation on the road today, almost guarantee it is at least 7-8 years old and probably more.

There is nothing wrong with the heat dissipation in the Camry headlight. Frankly, as noted, you are purely guessing and have no idea the Tc of the die is, and even if high, the failure rate from high die temp would be light degradation, not outright failure. That is almost always mechanical in nature.

 

[desert.snake]

Unless you are doing military or space, or infrastructure telecom, your design and testing is likely not nearly at the level of a small middle class car that has much more extensive and complete design and test that a low volume ultra high end car. The costs of high failure rates for cars is astronomical and hence avoided. You are showing you don't understand the process at all. Cars do breakdown, but less and less every year and I checked and no reports of unusual failure rates for Camry headlights.

I have not seen any car rust through in 2-4 years in 3+ decades and I practically drive in a salt spray 4+ months of the year where it is cold enough that salt is used all the time, but warm enough to have liquid/corrosion at near optimal rates. I put 30,000+ miles/year on cars for decades and never had perforation in < 7 years. With the galvanation processes, and multi-step painting processes, even on cheap cars, it just does not happen any more, hence 5+ year unlimited mileage perforation warranties. You may get the odd process failure but exceedingly rare. You see a car with perforation on the road today, almost guarantee it is at least 7-8 years old and probably more.

There is nothing wrong with the heat dissipation in the Camry headlight. Frankly, as noted, you are purely guessing and have no idea the Tc of the die is, and even if high, the failure rate from high die temp would be light degradation, not outright failure. That is almost always mechanical in nature.

Space.

If you have not seen such machines, then you are lucky. My friend in the car service sees 3-4 year old Japanese cars that are rusted through. The best in terms of corrosion protection are normal Germans. BMW, Mercedes, Audi - 30-40 years cars inside look like they came from the factory).

I already wrote, 2 headlight failures on a Camry from my friend. The LED is burned out.

 

[JustAnOldFashionedLEDGuy]

Space.

If you have not seen such machines, then you are lucky. My friend in the car service sees 3-4 year old Japanese cars that are rusted through. The best in terms of corrosion protection are normal Germans. BMW, Mercedes, Audi - 30-40 years cars inside look like they came from the factory).

I already wrote, 2 headlight failures on a Camry from my friend. The LED is burned out.

So a completely sealed, sonic welded assembly but you know the LED is burned out .... okay. Call me skeptical.

I think your friend has bias and/or is lying to you. I have had Nissan, Mazda, Honda, VW, BMW, Ford, Chevy, Toyota, and Lexus in the family over the last 30 years in a high salt environment, often 30,000+/year, most cars kept 6-9 years. The earliest rust issue was the Ford, followed by the BMW, and larger surface rust, no rust through. We did get perforation at 9 years with the Mazda, but it had 200K miles. 3-4 year is frankly, a load of crap. Hyundais and Dodge failed like that 30 years ago. No cars do that made in the last 2.5+ decades. 40 year old Audi's and BMW would rarely be on the road any more (terrible reliability) and if they were, they body was long gone if they were near salt. Now they are the best out there. Can't say I place a lot of faith in anything you claim.