Mini-LED technology is one of the fastest-growing innovations in modern display manufacturing. It’s used in ultra-thin TVs, in-car display panels, transparent screens, and even smart automotive windows.
To support this shift in display quality, manufacturers need high-precision inspection tools — and that’s where Hypersen’s HPS-LCX1000 3D Line Confocal Sensor comes in.
📌 What is Mini-LED?
Mini-LED refers to LED chips with sizes between 100 to 300 µm. These chips are mounted onto a base (usually a PCB or glass substrate) to create high-density LED arrays. Because the chips are so small and tightly packed, manual visual inspection is no longer effective.
🎯 The Inspection Challenge
During Mini-LED production, the base of the LED unit (called the Mini-LED base) needs to be carefully checked. Any defects can affect brightness, alignment, and product yield.
🔧 Measurement Targets:
Base dimensions (length, width)
Flatness and step height
Coating/glue thickness
Bump height
🛠️ The Solution: HPS-LCX1000
The HPS-LCX1000 is a 3D Line Confocal Sensor designed for non-contact, high-precision optical measurement. It is especially effective for surfaces that are transparent, reflective, or mirror-like — exactly the type of surfaces found in Mini-LED manufacturing.
✅ Key Sensor Features:
Z-axis repeatability: 0.1 µm
X-axis resolution: 1.1 µm
Captures both 2D profiles and full 3D shape data in a single scan
📊 Test Results
Using the HPS-LCX1000, a Mini-LED base was scanned, and the sensor provided precise measurements:
| Parameter | Measured Value |
|---|---|
| Base length | 3270.23 µm |
| Base width | 1244.62 µm |
| Flatness | 11.883 µm |
| Step height | 13.402 µm |
| Glue thickness / Bump height | 23.91 µm |
These results show how detailed and accurate the sensor can be, even on complex surfaces.
🔬 Why Use Line Confocal Technology?
Hypersen’s LCX1000 uses line-scan CMOS imaging and confocal technology to overcome challenges in traditional optical methods. It delivers:
High-speed scanning
High resolution imaging
No impact from surface reflectivity
This makes it ideal for inspecting modern display materials and ensuring high yield in Mini-LED production lines.
