Soldering a high-density LED array using DIY reflow oven

First of all, please watch the video below to find out how everything was done on my work bench.

A recent project requires soldering 600+ tiny LEDs on long narrow circuit boards. The LED, Philips Rebel Z ES, is as small as 1.6mm x 2mm, and is placed 2.5mm apart from each other. The leads of those LEDs are only on the bottom of the component, so apparently hand soldering is not possible.

Philips Rebel Z ES LED size vs. US quarter dollar
Philips Rebel Z ES LED size vs. US quarter dollar

Since I’ve built a DIY reflow oven before, I decided to push the boundary a littler further and give it a try. I’ve done many project using this DIY oven, but components’ density at this level is something I’ve never tried before. Carefully starting this project by designing proper circuit, I also tuned and laser cut the stencil, and finally got into this reflow process. Surprisingly, all those pieces worked together very well and got this job done!

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