Why Separate LED Designs Struggle in Mass Production

In the early R&D phase of micro-endoscope camera modules, the Separate LED design (where LED beads are externally mounted via thin wires) is a common rapid validation solution for engineers. It allows for flexible verification of lighting effects and imaging quality without altering the ultra-slim lens diameter (e.g., 1.05mm), making it highly suitable for prototype testing and sample creation.

However, when transitioning from lab samples to mass production, this design reveals several critical engineering bottlenecks, failing to meet commercial standards for reliability, durability, and aesthetics:

1. Reliability Challenge: Fragile Structure, Prone to Failure

• Unprotected Connections: The externally mounted LED beads and solder joints lack mechanical protection, making them highly susceptible to detachment or damage from repeated use or minor impacts.

• Fine Wires Break Easily: The extremely fine wires used to maintain a slim profile have poor flexural fatigue resistance. In scenarios requiring frequent probe bending, the internal metal conductors break easily, leading to lighting failure.

2. Durability Challenge: Inability to Pass Rigorous Testing

• Mass-produced products must undergo a series of reliability tests such as vibration, drop, and plug-cycle endurance. The physical structure of the Separate LED design often cannot guarantee stable performance under these stringent tests and long-term use, resulting in a significantly higher failure rate.

3. Process and Aesthetic Challenge: Poor Consistency and Unprofessional Appearance

• Unsightly Appearance: Exposed wires and LED beads appear crude and untidy, undermining the product's professional image and making it difficult to inspire customer confidence.

• Low Production Efficiency: Automated assembly is challenging, often requiring extensive manual soldering and fixing. This leads to high production costs, slow throughput, and poor product consistency.

Conclusion
In summary, the Separate LED design serves as an excellent design validation tool but not a viable productized solution. Mass-produced modules typically adopt more integrated approaches, such as encapsulating micro-LEDs around the lens with more robust processes or using fiber optic bundles for light guidance. These methods ensure extreme miniaturization while meeting the absolute commercial requirements for reliability, durability, and manufacturing quality.