Lighting Sciences Group becomes largest producer of LED bulbs in North America

By Margery Conner | January 30, 2012

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I first heard of Lighting Sciences Group (LSG) back in 2007 as being the company that designed and built the LED replacement for the Times Square ball that drops on New Years Eve; I thought it was strictly an engineering design firm. And then its LED light bulbs started showing up in Home Depot stores. Last year at the Google I/O conference, LSG was the first company Google teamed up with for a Android@Home partner, specifically for intelligent lighting.

So clearly this is a company on the move. Yesterday the company announced it’s now the largest producer of LED light bulbs in North America, producing 4.5 million LED light bulbs in 2011. I immediately assumed that LSG sub-contracts its manufacturing to Asian companies, because that just seems to be the way it’s done these days, and asked the company where and by whom the bulbs are manufactured. The answer: LSG owns two production facilities, a smaller one at its headquarters in Satellite Beach, FL, with the majority done at its facility in Monterey, Mexico. All light bulb production workers, totaling about 700, are LSG employees, with another 300 employed in the US in engineering, research and sales.

It plans on opening another manufacturing facility in India, for sale of LED bulbs to both the subcontinent’s and Asian markets.

With manufacturing quality problems looming as the biggest obstacle to consumer adoption of LED bulbs, LSG apparently feels it must keep control of the whole design/manufacturing process to ensure mass-produced, quality products. True, at present most of the work is done in Mexico, but keeping initial production in the US is probably a small victory for US manufacturing going forward.

Contrast LSG’s approach, however, with Philips L-Prize bulb, which will have the majority of its US bulb manufacturing done in the US.

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Manufacturing problems are not holding LED bulbs back (Although they will as third on the list). #1 is that they do not do the job - they don't put out enough light, and they are highly directional. Phillips L-Prize bulb seems to have licked the directionality, albeit with a more complex design with phosphors on the inside of the globe, but that is a mature technology. But they still do not put out enough light. They need to put out 100W level of light (1600 lumens) AND they need to fit into the installed base of sockets (Speaks to base geometry), AND they can't be too tall (speaks to fixture) #2 is price vs. claimed life. $0.25-$0.50 per thousand hours will get my attention. #3 is reliability - will it reach its claimed life most of the time and often last much longer. Overriding all of this is will they catch fire. Incandescent bulbs get real hot, and fixtures and installations are designed to accomodate that safely. But they *never*, under any conditions, put out more heat, risking a fire. CFLs do on occasion, and I don't see why LEDs would be any different.

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