More and more different brands of red light therapy panels are appearing on the market, with high and low prices and varying quality. So today, ShineNova, China’s leading manufacturer of red light therapy panels, will show you how to manufacture high-quality red light therapy panels in our factory. ShineNova manufactures top red light therapy panels combining advanced LED technology, superior engineering, and strict quality control.
Contents
Market Research
1. Target Market Analysis
Market Size and Growth Trends:
The red light therapy market is experiencing significant growth due to the rising demand for healthy lifestyles and new, painless, drug-free treatment options. According to market research organizations, the global LED light therapy market has been growing at a compound annual growth rate (CAGR) of over 4.6% in recent years. The global light therapy market size is expected to increase to USD 1.44 billion by 2033 from USD 1.05 billion in 2023. This trend is expected to continue as advancements in technology and the expansion of application scenarios drive further market growth in the coming years.
Google search trends of red light therapy panel
Countries and Customer Segments:
Red light therapy panels can be categorized by application scenarios into home use, doctors’ offices and clinics, gyms, wellness centers, and others.
Currently, red light therapy panels are mainly popular in North America and Europe, and ShineNova’s red light panels are also mainly sold in the United States, Canada, Australia, the United Kingdom, Germany, the Netherlands, and other countries.
2. Consumer Demand Survey
Functional Requirements:
Consumers’ requirements for LED red light panels mainly include 1. LED wavelength selection: optimal wavelengths for red light therapy, typically around 630–660 nm (red) and 810–850 nm (near-infrared). These wavelengths are scientifically proven to penetrate the skin and tissues effectively. 2. light intensity adjustment: 100%, 80%,60%, 40%. 3. pulse adjustment:10hz and 40hz. 4. Timer function: 5 minutes, 10 minutes, 15 minutes, 30 minutes, 45 minutes, and 60 minutes.
Appearance and Size Requirements:
Home users prefer small, attractive, easy-to-operate red light panels, such as ShineNova’s SN300 and SN500. Gyms and wellness centers require large quantities of high-power, large-size red light panels, such as ShineNova’s SN1500, SN750, and SN1000. Larger panels will be customized in bulk according to the customer’s needs.
ShineNova SN1500 Red Light Therapy Panels
3. Competitive Analysis
Competitive Product Characterization:
Analyze competitors’ products in terms of whether they use high-quality raw materials, the precision of red light wavelength, light uniformity, irradiance, and lifetime. ShineNova produces high-end red light panels that use Epistar’s top LED chip, which can provide a very accurate spectral combination, high irradiance, and light uniformity that can reach more than 90%, the product service life up to 100,000 hours; while some low-end products may be single spectral, uneven light, low irradiance, shorter product service life, and bad after-sales service.
Industrial Design
1. Design Concept and Style
Based on User and Market Demand:
ShineNova’s sales target is the high-end market, and the design concept focuses on “aesthetics combined with lightness and convenience”. We designed the red light panel with a modern technology style, using simple lines and soft colors, such as white, so that it can be integrated into the modern home environment. At the same time, our structural design of the panel should be convenient for the user to install and adjust, such as the use of armrests and mobile stands, so that the user can flexibly adjust the light angle and direction of the panel according to whether they are using it standing up or lying down.
ShineNova SN1500 red light panel with horizon stand
2. Appearance Design
Model shape:
The overall shape of the panel should be ergonomic and aesthetically pleasing, making the panel itself decorative. Small desktop LED red light panels can be designed in a rounded shape, avoiding sharp edges and corners to prevent users from being injured during operation. Consider the portability and storage of the product. The design can come with handles or mobile structures that are easy to carry, making it convenient for users to move and use the product in different indoor spaces, and it can be easily stored when not in use.
Color and material selection:
Color should be considered for the consumer’s visual perception. In general, the panel shell color should be light, avoiding dark colors that absorb too much heat to affect the lamp’s and lantern’s heat dissipation. At the same time, the light-colored shell can also give people a fresh and neat feeling. In the choice of materials, the shell can be made of aluminum alloy or plastic, but the manufacturing cost is high. Usually, iron is used as the shell, while the surface can be anodized to increase the texture and corrosion resistance.
3. Circuit Design
Power Supply:
According to the power requirement of the LED red light panel, design a power supply circuit with over-voltage protection, over-current protection, and short-circuit protection to prevent the LED chip from being damaged due to an abnormal power supply. Choose the right power supply with multiple certifications, such as UL, ETL, CE, and FCC. This includes choosing the right power supply chip, such as a constant current driver chip, to ensure that the LED chip can work stably. The efficiency, safety, and EMC of the power supply should also be considered.
Control Circuit:
Design control circuits to realize the control of various functions of the red light panel. For example, design a circuit that can adjust the light intensity and realize the dimming function by changing the amount of current input to the LED chip, or design a timer circuit that allows the user to set the panel’s on and off time. If intelligent control functions need to be realized, interface circuits with sensors (e.g., infrared sensors), communication modules (e.g., Wi-Fi, Bluetooth), and language modules also need to be designed.
4. User Interface (UI) Design
Ease of operation:
Designed with an easy-to-understand user interface, the large LCD screen for adjusting wavelength, light intensity, and pulses makes it easy for the user to get started and select treatment or customized modes. For red light therapy panels with a timer function, a clear digital display can be set to show the remaining time or a countdown timer, which is convenient for users to set and check the timer status.
Design sketch of ShineNova red light panel
Structural Design
1. Optical Systems Design
LEDs Selection and Layout:
Depending on the depth of light penetration into the human skin and the therapeutic characteristics, red light (630nm, 660nm) and near-infrared light (810nm, 850nm) are the key wavelengths, and high power and high-brightness LED chips from top brands of are preferred, such as Epistar. In terms of light layout, to realize the requirement of light uniformity, a matrix layout is adopted, which makes the LEDs of different wavelengths arranged in a manner and evenly distributed on the panel.
Optical Lens and Reflector:
An optical lens is made of PMMA material, with high transmittance and good optical performance, used to focus the light, which can make the light shine evenly on the body. Using a 30-degree lens can focus the light on a specific area and increase the localized light intensity. A reflector can reflect backward light from an LED chip to increase forward light intensity. A well-designed reflector shape, such as a parabolic reflector, can focus the light forward and increase the light energy utilization of the red light panel.
2. Cooling System Design
Heat Dissipation Method:
Commonly used heat dissipation methods include natural convection heat dissipation, fan heat dissipation, and so on. For the LED chips inside the red light panel, aluminum substrate heat dissipation is used to increase the contact area with the air and use the natural flow of air to take away the heat. High-power red light therapy panels, especially in commercial application scenarios where they are used for long periods of time, require the installation of a fan to accelerate airflow and improve heat dissipation efficiency.
3. Mechanical Structural Design
Casing Structural of Panel:
The panel casing should provide sufficient mechanical protection to prevent the LED chip and other internal components from external impact damage. The outer layer is a hard metal iron casing, which is screwed in such a way that the casing can be easily opened and closed for easy installation and disassembly, making it convenient for users to carry out maintenance and replacement of components.
Manufacture of red light panel housings
Internal Fixing Structure:
For the connection between the various components inside the panel, make sure the connection is firm and reliable. The connection between the LED circuit board, relay, driving power supply, and the shell adopts the screw combination way to ensure that the circuit board will not loosen when it is subjected to vibration or external force.
Production Process
1. Raw Material Purchasing and Inspection
Purchases:
According to the design and BOM forms, we purchase raw materials in large quantities from our long-term top suppliers. These materials include LED chips, circuit boards, optics (such as lenses and reflectors), housing materials (both plastic and metal), power supply components, holder materials, and other necessary raw materials. Ensure that the quality of raw materials meets the design requirements. For example, LED chips should be purchased with a stable spectrum and brightness, and circuit boards should comply with electrical safety standards and wiring requirements of the design.
Inspection:
Inspection of raw materials. For LED chips, use a spectrometer, brightness meter, and other equipment to check it’s their spectral characteristics and brightness, among other parameters; for circuit boards, carry out electrical performance tests, such as checking whether the line is on,s are functional and whether the insulation performance is good adequate, etc.; for the shell material to, check the quality of its appearance, dimensional accuracy, and physical properties (eg.g., strength, hardness); for optical components to, check the optical properties (eg.g., transmittance, refractive index). Only qualified raw materials can enter the production process.
2. Small Batch Trial Production
Before the official mass production, small batch trial production is carried out. This helps us verify the feasibility and stability of the production process and check whether the product quality can meet the design requirements. In the small batch trial production process, we will record various data, such as raw material consumption, production hours, product qualification rate, etc., to optimize the production process.
3. Mass Production
Make Production Plans and Scheduling:
ShineNova develops mass production plans based on market demand and sales forecasts. This includes determining the production quantity, production cycle, and raw material procurement plan. At the same time, we will rationalize the arrangement of production personnel and equipment to ensure that the production process is efficient and orderly.
ShineNova produces red light panels in the factory
Assembling:
We make a red light therapy panel assembled with LEDs, circuit boards, optics, housings, a power supply, and other components. Firstly, the circuit board will be mounted inside the housing and fixed by screws; then the lens and reflector will be mounted correctly to ensure that they are positioned accurately and can effectively control the distribution of light; finally, the power supply will be mounted according to the power supply, which will be assembled into a complete ShineNova red light therapy panel. During the assembly process, we will carry out electrostatic protection to avoid static electricity damage to electronic components.
Functional Testing:
After the panel assembly is completed, we will debug all red light panels. This includes checking the optical performance again (such as light intensity, light uniformity, spectral distribution) to ensure that it meets the design requirements; checking whether the electrical performance (such as power, power factor, current, voltage) is normal, making sure compliance with certifications such as CE, FCC, RoHS, and UL ensures the product meets global safety standards; testing various functions (such as remote function, timing function, intelligent control function) whether it can be realized normally.
Each ShineNova red light therapy panel undergoes rigorous testing for power output, wavelength accuracy, and light intensity distribution. ShineNova panels are also tested for longevity and resistance to environmental factors like heat and moisture. If any problems are found, we will make timely adjustments and repairs.
Quality Control:
During mass production, we strictly monitor production parameters to ensure that the quality of each product meets established standards. To enhance both production efficiency and product quality, we use automated Surface-Mount Technology (SMT) production lines employed for LED welding, leading to improvements in both welding speed and quality.
Comprehensive quality inspection of the panels after production. In addition to the inspection of the optical properties, electrical properties, and functions of the product, we also check the appearance quality of the product, such as whether there are scratches on the shell, whether it is deformed, and so on. Rejection of any non-compliant products sold on the market.
ShineNova SN1500 red light therapy panel irradiance
Packaging:
At ShineNova, only qualified products can enter the packaging process. Our packaging is divided into neutral packaging and branded customized packaging; manuals, warranty cards, and user guides are placed according to customer needs. Our red light panels are packaged securely to prevent damage during transportation. We use suitable packaging materials (e.g., cartons, foam, etc.) to ensure that the products are not damaged during transportation and storage.
Storage in Warehouse:
The packaged panels are warehoused in accordance with the storage requirements specified by ShineNova. Our storage environment is kept dry and ventilated to avoid the products being affected by humidity, high temperature, and other adverse conditions. Meanwhile, records will be kept on the stored products, including product model, quantity, production date, and other information for easy management and sales.
After-Sales Service and Feedback
When the panels are sold, we will provide after-sales service, including product installation guidance, fault repair, technical advice, etc. We are happy to listen to feedback from users, such as problems that occur during the use of the product, and users’ suggestions for product improvement. Based on user feedback, continuous improvement of the panel’s design and production process is carried out to improve product quality and user satisfaction.
ShineNova’s Manufacturing Experience
Suppose you would like to customize Red Light Therapy panels to your company’s brand. In that case, you can contact our sales representative, send us your design file, and we will have an engineer assess the feasibility and cost of the project. Thanks to our customers’ trust and choice of ShineNova, LED red light therapy panel production volume has reached 100,000 units in the past 3 years.
Benefit from our strict control of raw material incoming inspection, production process optimization, and staff proficiency improvement, which reduces the product defect rate, improves the smoothness of each production process, effectively reduces downtime and production stagnation time, and the good cooperation between every department, which makes the quality of the red light panels we produce recognized by our customers.
