Category Archives: LED Packaging and Testing

February 8, 2012 — The global high-brightness light-emitting diode (HB-LED) market grew from $11.3 billion in 2010 to $12.5 billion in 2011, surging 9.8%, according to Strategies Unlimited. 10 companies accounted for more than 68% of the global LED supply.

Demand for LED components in the lighting market grew 44% from 2010 to 2011, from $1.2 billion to $1.8 billion.

Table. Top 10 LED suppliers for 2011, by revenue of packaged LED components.*
1 Nichia
2 Samsung LED
3 Osram Opto Semiconductors
4 LG Innotek
5 Seoul Semiconductor
6** Cree
6** Philips Lumileds
7 Sharp
8 TG
9 Everlight
*Strategies Unlimited arrived at these figures after analyzing market demand as well as the supply-side activity of more than 54 LED component suppliers.
**Companies have the same ranking when the difference in revenue is within the margin of error. Revenue includes packaged LED sales only.

Taiwanese and Chinese suppliers gained market share at the expense of the other regions in 2011. China leapt from 2% to 6% market share on the strength of its domestic market, as well as improvements in LED quality. Korean companies lost share, despite aggressively increasing capacity during the ramp-up in 2010. Japan trended down or flat, although Nichia and TG are tapping into tablet growth.

Philips Lumileds, Cree, and Osram Optoelectronics’ expansion into 6" wafers slowed, with excess capacity available on their 4" wafer lines. Osram Optoelectronics gained a major design win, which propelled its visible LED component business to more than $1 billion.

Figure. 2011 worldwide distribution of LED supply. SOURCE: Strategies Unlimited.

The revenues for the LED packaging industry are expected to be flat in the next five years. With excess capacity in the industry there is a threat of unsustainable prices.  Consolidation, vertical, and horizontal can help improve margins. To further improve profit margin, product strategies such as LED packages tested for high temperature, narrow binning, high CRI, directional /multidirectional LEDs, and embedded controls are being tried by the market.

Mobile. This segment stayed flat, at $3.4 billion. The overall decrease in the mobile phones market was offset by a sharp rise in tablet display and flash applications. A major development in this segment is the move to organic LED (OLED) displays. Approximately 50% of smartphone displays are expected to be OLEDs by 2016.

TV/monitor backlight. The LED revenue for TV and monitor backlights was $3 billion in 2011, but it is projected to drop substantially by 2016. The key disruptive factor in this segment is the introduction of low-cost direct backlit technology, targeted at sub-42-inch LCD TVs. This new technology can result in significant savings in the BOM, reducing the gap between LED and CCFL backlit TVs. These TVs are known as “Chubby TVs” since they are thicker than the slim edge-lit design the industry has been touting for the past few years.

Lighting. The same supply conditions that reduced the price of LEDs increased the demand for packaged LED in lighting applications from $1.2 billion in 2010 to $1.8 billion in 2011. System efficacy, rather than LED efficacy, was the gating factor in 2011. The LED luminaire and replacment lmap market was $9.3 billion in 2011, an increase of 45% over 2010. The market for LEDs in lighting is expected to demonstate substantial unit growth over the next five years, but revenue growth will be much lower due to pricing pressure.

Automotive. Revenue reached $1 billion in 2011 We expect a 5-year CAGR of 34% for LED headlamps. In addition to the styling issues, this is part of the trend to convert all front lighting to LEDs, as it will provide more front-end room for the car designer and reduce the overall system cost. Revenue for interior automotive lighting will show a modest decline over the next five years as instrument panel adoption reaches saturation and the market declines with prices.

Strategies in Light Conference & Exhibition 2012 is taking place this week in Santa Clara, CA. For more information, contact Strategies Unlimited at +1 650 941-3438 (voice) or e-mail at info@strategies u.com, or visit www.strategies-u.com.

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February 8, 2012 — The 2012 Strategies in Light conference kicked off today at the Santa Clara Convention Center with a series of five workshops, two tutorials and one all-day investor forum. The investor forum is where I chose to spend my day, as it provided the opportunity for solid state lighting and related startups to talk about their technologies, products and implicitly the opportunities they provide for investment. The forum was well populated by actual investors looking for opportunities to trade-in their Maseratis for something a bit more upscale.

Vrinda Bhandarkar at Strategies Unlimited presented a global market review for LED lighting. Not surprisingly, the largest available market is China, but the greatest number of individual LED replacement lights sold last year was in Japan, their high price notwithstanding. The market for luminaries is expected to be $20B by 2016 with a CAGR of 19%. Over the same period replacement lights will grow to $3B with a CAGR of 23%. The LED lighting cost index has the potential to drop from 100 today to 20 by 2015, but that will require achievement of efficiencies across the entire component set.

HelioDel is a spin out of CEA-LETI that claims a 5x cost reduction breakthrough by using grown GaN nanowires in place of planar device structures. This enables the generation of a range of controlled colors on a single chip, with the prospect of eventually eliminating the need for phosphors altogether.

Just as CFL technology was met with consumer resistance due to the its color, LED lighting is subject to consumer criticism due to flickering associated with the incoming alternating current. In an environment that is illuminated totally by LEDs, there is a segment of the population that reacts adversely with symptoms ranging from headache and eyestrain to epileptic seizures. Privately-held iWatt Inc. is a four year old company that manufactures digital control LED power supplies that are already implemented worldwide to improve the human factors associated with LED lighting.

Xicato has taken the novel approach of separating the photon generation from the color tuning by using commodity LEDs with something called Corrected Cold Phosphor Technology™. The color temperature of the lighting unit is determined by placing the phosphors in a translucent cover disk that is spatially separated from the LED devices. Furthermore, the disk is integrated into the cooling system, so that its color remains constant over a lifetime of several years and is highly uniform from one device to the next.

CoolEdge Lighting is a stealth startup spun out from the University of Illinois that is commercializing an all-plastic flexible “light engine” that does not require heat sinks or wire bonding. Small commodity LEDs are used from four foundries. General Manager Wade Sheen assured the audience that development of the product is based entirely on good engineering; magic was not invoked.

The conference continues for the next two days with a technical conference and supplier exhibition. Read Fury’s reports from Days 2 and 3:

Michael A. Fury, Ph.D., is director & senior technology analyst, Techcet Group in North Plains, OR.

February 3, 2012 — The global market for power supplies used in LED lighting is forecast to reach $10 billion in 2016, according to a new report from IMS Research.

"Opportunities for Power Components in LED Lighting" from IMS Research reveals that rapid uptake of LED lighting, driven by legislation and rising costs of electricity, will result in a potential market of 4 billion power supply units by 2016, worth an astounding $10 billion. Report co-author and senior market analyst, Ryan Sanderson, commented “Demand for LED lighting solutions is increasing rapidly for all applications from low-power residential retrofit LED lamps and bulbs to high-power commercial and industrial LED luminaires for applications such as street lighting.”

Figure. World market for power supplies in LED lighting by revenue. SOURCE: IMS Research January 2012.

The report also found that the traditional lamp and luminaire market is well established. Manufacturers are faced with new challenges when it comes to powering LED lamps and luminaires and often require significant power electronics expertise, opening up opportunities for power supply manufacturers. The requirements to power new LED lighting products varies widely, depending on design factors including power rating, the number of LEDs or LED strings and the environment in which the solution will be placed. Sanderson added, ”These design requirements, coupled with the lack of clear standards for LED lighting means that LED lamp and luminaire manufacturers need considerable power electronics expertise, either via employing specialists or from a merchant power supply manufacturer.”

The market report found that LED lighting would become a unique opportunity, despite the fact that general lighting has always been a relatively small and low-growth market for the power supply industry. Competition in lighting, however, is already fierce and some of the largest manufacturers of LED lamps and luminaires are positioning themselves to cope with these challenges internally. Report co-author and market analyst, Jonathon Eykyn, commented “Some of the largest manufacturers of LED lamps and luminaires already have the capability to design and manufacture power circuitry in-house, either via subsidiaries or through the acquisition of power supply manufacturers. Philips Advance is a prime example”. This means that a portion of the total power supply opportunity is absorbed by these vertically integrated companies and becomes “captive”. Eykyn added, “Designing and manufacturing the power solution in-house, however, only really makes sense in high-volume, low-cost markets and where the design is simple; for example, LED retrofit lamps. In medium and high-power applications, design becomes more complex and it often makes more financial sense to outsource the power supply design to a merchant vendor.” As a result, the report from IMS Research forecasts that more than 50% of the market in 2016 will be controlled merchant power supply manufacturers.

IMS Research is a leading independent provider of market research and consultancy to the global electronics industry.

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February 3, 2012 — Hanwha L&C of Korea signed a letter of intent (LOI) to obtain manufacturing and distribution rights to ElectriPlast from Integral Technologies Inc. (OTCBB: ITKG) (OTCQB: ITKG), hybrid conductive plastics maker. The LOI is applicable for various parts of Asia.

ElectriPlast is a non-corrosive, electrically conductive resin-based material that can be molded into various shapes and sizes, reducing component weight by up to 40% compared to plastics, rubbers and other polymers. Applications include power electronics, light-emitting diodes (LEDs), connectors, batteries, semiconductors, sensors and antennae, and more.

Independent testing of ElectriPlast, over several months, showed that it met or exceeded Hanwha L&C’s conductivity, shielding (both electric and electro-magnetic) and mechanical strength requirements.

Specifically, the LOI contemplates Integral and Hanwha L&C entering into definitive agreements granting an exclusive license to manufacture and distribute ElectriPlast in Korea. The LOI further contemplates a non-exclusive license to distribute ElectriPlast in China, Japan and Taiwan, as well as a right of first refusal to extend the exclusive license to manufacture in Korea to China, Japan and Taiwan and to make the non-exclusive license to distribute in China, Japan and Taiwan an exclusive license.

The LOI is non-binding and calls for the completion of certain milestones by the parties. Definitive agreements could be executed as early as H1 2012.

Integral Technologies Inc. engages in the discovery, development, and commercialization of electrically conductive hybrid plastics used primarily as raw materials in the production of industrial, commercial and consumer products and services worldwide. Integral is the original researcher, developer and 100% owner of all intellectual property surrounding the ElectriPlast technology, and markets the ElectriPlast product through Integral’s wholly owned subsidiary, ElectriPlast Corp.

Hanwha L&C is part of the Hanwha Group, a global diversified company with nearly $30 billion in annual revenue that operates in three main sectors: manufacturing & construction, finance and services & leisure. Hanwha L&C is in the construction materials field and has expanded into auto lightweight materials, electronic materials, and photovoltaic materials, as well as other high-value pioneering industries.

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January 31, 2012 — The Thick Film Division of Heraeus Precious Metals has announced a new name, Celcion, for its Insulated Aluminum Materials System. Celcion allows light emitting diode (LED) circuits to run cooler than metal-core printed circuit boards (MCPCBs).

Celcion, a Thick Film Materials System designed to insulate aluminum substrates, takes the same fit and form as traditional MCPCBs, while providing thermal conductivity and high dielectric breakdown strength. It is a simplified additive process that is faster, easier to use, and requires less materials than MCPCBs. The system allows circuits to be built directly onto aluminum substrates, eliminating the need for thermal interface materials (TIMs). This allows Celcion circuits to run 10°C cooler than MCPCBs.

Also read: LED test standards, packaging material challenges

Traditionally, MCPCBs are constructed using a subtractive process. Celcion features a selective additive process, applying material only where it is needed. It is reportedly faster with less waste, and enables inexpensive, fast-implementation design changes.

Figure. Actual thermal reading of LED circuits. Celcion-packaged LED reading is on the bottom. SOURCE: Heraeus.

With cooler circuits, fewer LEDs can be used to achieve the same light output. This suits high-power applications, such as general illumination, signs, signals and displays. It also offers increased performance benefits in power electronics, heaters and automotive manufacturing.   

Heraeus will feature Celcion at Booth 508 during the Strategies in Light 2012 conference and exhibition, Feb. 7 – 9, Santa Clara, CA, Booth 508. Through live, on-site product demonstrations, Heraeus will show how Celcion is used in manufacturing LEDs, and why it is a viable alternative to traditional MCPCBs.

Heraeus launched a website, http://celcionled.com/, to showcase the Insulated Aluminum Materials System. A video on the site describes the differences between the traditional MCPCB process and Celcion, and how LED performance is increased.

Heraeus Precious Metals North America Conshohocken LLC, Thick Film Division, is a worldwide supplier of thick film pastes, LTCC materials and precious metal powders to the hybrid microelectronics industry. The Thick Film Division offers products for thermal management applications, including LED packaging, power modules, and electronic heating units.

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January 30, 2012 — Gamma Scientific, light measurement instrumentation maker, introduced a low-cost spectrometer for quick and accurate testing for light-emitting diodes (LEDs). The RadOMA Lite linear CCD array spectrometer tests LED intensity and total flux.  

With near real-time speed and NIST-traceable measurement, the RadOMA Lite accepts an SMA905 fiber-optic input that can be connected to a various optics, including integrating spheres for total flux measurements or CIE127 Conditions A and B for intensity measurements. The RadOMA Lite features an 800kHz readout speed and slit options that can achieve resolutions between 0.5 and 3.0nm.

The custom RadOMA-Lite Windows software package for LEDs includes a simple, intuitive interface with automated report generation and a USB 2.0 interface.

Flexible custom configurations and application support are also available.

RadOMA spectroradiometers use a backside-thinned CCD detector with Gamma Scientific’s OMA optical multi-channel analyzer platform. The detector is a CCD Linear Array – 2048 pixels – 14μm x 200μm sensing pixel size – 1800 V/(l*s) @660nm sensitivity. It covers a spectral range of 380-780nm. Gratings: 600G/mm.

Gamma Scientific will be showcasing the RadOMA Lite and their complete line of LED test and measurement solutions in booths 501 and 600 at the Strategies in Light conference in Santa Clara, CA from February 7-9, 2012.

Gamma Scientific offers solutions for the LED and Solid-State Lighting (SSL) industries, ranging from single-device characterization to high-volume production testing, as well as measurement of integrated lamps and lumenaires. Learn more at http://www.gamma-sci.com/applications/led_test_measurement/.

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Last year has been an outstanding one for LED-related equipment sales. However, this former bright sky overclouds for capital expenditures in 2012, and many market analysts project around 18% decay for this years’ equipment sales. But to keep things straight, this number is mainly related to MOCVD sales, making up for about 50% of the LED equipment pie in one fab. In fact, downstream processes — including lithography, bonding, testing or packaging — are expected to further increase in capex for 2012.

Changing requirements

Traditionally, the most important factor for LED manufacturers has been tool cost. This was especially true for any downstream process after MOCVD growth. Today, these requirements are changing. More complex chip layouts for higher lumen output and increased LED efficiencies demand more sophisticated processes and equipments. Having said that, the focus of LED makers is shifted to more traditional values of equipment requirements, such as higher automation, enhanced yield and increased throughput.

It’s all about efficiency

Based on the Department of Energy LED manufacturing roadmap, costs are still a factor of 5-8 too high to trigger mass adoption of solid state lighting technology and efficiently compete with alternative technologies. This cost target directly rolls back to LED manufacturers and hence the equipment supplier, demanding for more efficient manufacturing technologies. Therefore, three general decision factors have been established, namely capital efficiency, footprint efficiency and cost of ownership. Capital efficiency basically tells the number of processed wafers per unit time for any capital dollar spent. Footprint efficiency gives the wafer output per unit time for any square-metre of fab space. Efficient use of precious fab space is very closely linked to how profitable a LED fab can be operated. Combining these factors lead to cost of ownership, being traditionally used in semiconductor industry rather than the LED industry.

Applying the above metrics to any process step illustrates their importance. As an example, optical lithography is the general applied patterning technique for LED manufacturing. With three to seven lithography layers – depending on application and LED complexity – any advantage in these metrics is multiplied several times. Thus, mask aligners can considerably leverage manufacturing cost. The newly developed EVG620HBL has been optimized according to these metrics. The system delivers industry-leading throughput and more than 20% increased capital efficiency as well as footprint efficiency.

Upcoming technical challenges

Another hot topic is patterned sapphire substrates (PSS), which enable higher light extraction and a reduced defect density. Looking into the future, feature sizes of PSS will be further minimized into the sub-micrometer range, leading to so-called nanometer PSS (NPSS). These NPSS substrates show considerable advantages, including further reduced defect density and increased extraction efficiency compared to micron-sized PSS. In this way, the overall LED efficiency is improved. Even a comparatively small increase in overall LED efficiency can considerably reduce the required chip area for a certain lumen output. Hence, LED efficiency is an important lever for cost reduction. Furthermore, when using NPSS, cost reduction is enabled by shortened sapphire etching and shortened growth time in the MOCVD, due to reduced feature size of NPSS substrates. On the other hand, manufacturing cost of NPSS is the same as standard PSS. With nano imprint lithography (NIL) and PHABLE, EVG has two different, cost-efficient technologies implemented in its portfolio.

In conclusion, with MOCVD market saturation, the focus of the LED industry is shifted to downstream processes. Increasing process yield and cost efficiency will be a central aspect for future equipment decisions of LED manufacturers. Advanced manufacturing technologies, to increase overall LED efficiency, are generating added value to current process flows.

Thomas Uhrmann (left) is Business Development Manager, EV Group, and Thorsten Matthias (right), is Business Development Director, EV Group.

 

January 20, 2012 – BUSINESS WIRE — LED manufacturer Seoul Semiconductor Co. Ltd. has applied, registered, and secured more than 10,000 patents for light emitting diodes (LEDs) globally. The company holds a patent portfolio across a broad range of technologies and processes, including material, design, manufacturing and methodology.

Seoul Semiconductor invests 10-20% of its annual revenue in research and development, including funding of an affiliate company. Seoul Semiconductor’s strategy is to hold a large number of patents, and cross-license with major LED corporations, noted Brian Wilcox, vice president of Seoul Semiconductor, saying "R&D is our future and patents heighten our competitiveness."

The company holds patent rights for Acrich, a semiconductor light source using a multi-cell architecture. Starting in 2012, Seoul Semiconductor expects increased business activity from the Acrich2 AC LED technology, as it goes into production. The LED maker also has patent rights for deep UV LED technology, which it expects to be a future commercial success.

Seoul Semiconductor is a top LED supplier with a range of LED technology and production capacity in areas such as deep UV LEDs and non-polar LEDs, as well as Acrich AC LEDs. Learn more at http://www.acriche.com/en/.

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January 18, 2012 — Consumers are adopting LED-backlit LCD TVs more slowly than expected, prompting TV makers to design lower-power, lower-cost LED backlights using fewer LEDs per TV set, shows the NPD DisplaySearch Quarterly LED Backlight Report. Fewer LEDs means lower brightness, thicker designs, and a hit to picture quality.

These new LED backlights use about half as many LEDs, and replace light guide plates, optical film, and other materials with lower cost diffuser plates and lens structures on the LEDs. TV makers have been adopting 2-chip LED packages to reduce the number of packages and to reduce optical film use. The number of LED packages used per set with direct backlights is expected to be less than that of sets with edge backlights.

Also read: GaN LED market growth starts in 2012

Figure 1. Backlight cost forecasts for 32” HD 60 Hz LCD TV Panel. Source: NPD DisplaySearch Quarterly LED & CCFL Backlight Cost Report.

The reduction in LEDs and other materials lowers power consumption, but requires a thicker profile. Brightness is lowered to 300 nits as opposed to 450 nits for edge-lit LED or CCFL, and lack of dimming reduces the contrast ratio and image quality.

Figure 2. Forecast of LED packages per TV set. Source: NPD DisplaySearch Quarterly LED Backlight Report.

"LED penetration in LCD TV was 7 points lower than our forecast a year ago, mainly due to high LED premiums. The premium for a LED backlight in a 32" LCD TV was 42% in Q4 2011, although it had been expected to fall to 27%," said Yoshio Tamura, SVP, NPD DisplaySearch.
Lowering power consumption and price brings LED-backlit TVs into the cost-competitive range with CCFL-backlit LCD TVs, and even CRT TVs. The materials cost for direct LED backlights comes closer to that of CCFL backlights. NPD DisplaySearch estimates that for 32” LCD TVs, direct LED backlights cost 1.3-1.4x CCFL backlights, as opposed to edge-lit LED backlights (2x+ CCFL cost). For 40” LCD TVs, the savings could be even greater.  

LED backlight penetration is likely to continue to ramp, added Barclays Capital, reporting on what the firm saw at 2012 International CES in Las Vegas this month. Direct-lit TVs are likely to remain in the premium niche of the market, Barclays warns, adding that "LED industry overcapacity is unlikely to stabilize in 2012, suggesting another year of 25+% Y/Y ASP declines."

Companies at CES:
Samsung’s non-organic LED TV line-up for 2012 highlights strong focus on LED-lit models, suggesting potential upside to our LED TV penetration forecast of ~68% in 2012, with management indicating the LED TVs are likely to be "mainstream" for the industry in 2013, Barclays reports.

Sony’s newly introduced Crystal LED display technology has the potential to meaningfully expand LED chip units per screen (~6M tiny LEDs for a 55" screen vs. 100-200 for an edge-lit model) but the technology remains in prototype phase. New display technologies like Sony’s CrystalLED display have the longer-term potential to boost unit demand, Barclays predicts.

The NPD DisplaySearch Quarterly LED Backlight Report is a quarterly update of the entire value chain for large-sized TFT LCD backlight units: technological developments, industry news, price trends, supply/demand, cost structures and more. For more information on these reports, please contact Charles Camaroto at 1.888.436.7673 or 1.516.625.2452, or [email protected] or contact your regional DisplaySearch office in China, Japan, Korea or Taiwan. NPD DisplaySearch is a global market research and consulting firm specializing in the display supply chain, as well as the emerging photovoltaic/solar cell industries. Visit http://www.displaysearch.com/.

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January 17, 2012 — The gallium nitride (GaN) light-emitting diode (LED) market declined in 2011, but 2012 marks the beginning of a growth curve, with double-digit growth in 2013 and 2014, says IMS Research. Lighting revenues will overtake TV revenues for GaN LEDs a year earlier than expected.

After 60% growth in 2010, the GaN LED market fell 6% in 2011 to $8.0 billion, shows IMS Research’s Quarterly GaN LED Supply/Demand Report.

Figure. 2009-2016 packaged GaN LEDs by application (Revenues by segment; billions of dollars). SOURCE: IMS Research.

A widening surplus is resulting in significant pricing pressure: supply grew nearly 3X faster than demand from 2010 to 2011. LED factory utilization levels are depressed. IMS Research’s report shows that the LED surplus rose from 7% (healthy) in 2010 to 45% in 2011, and will continue in 2012.

With both panel shipments and LED penetration below expectations and average LED prices for backlighting declining 34% on a volume weighted average basis on depressed utilization, backlighting revenues fell 13% to $4.8B in 2011. ASPs for certain backlighting markets were down as much as 45% last year. As a result, backlighting fell from 64% of 2010 GaN LED revenues to 59% of 2011 GaN LED revenues and are likely to continue falling on a percentage basis in the future, as backlight markets become saturated and the lighting market accelerates.

LED revenues for TVs are expected to fall 5% in 2011 to $1.9B as penetration is only expected to reach 39%, down from the previous estimate of 43%.

However, the GaN LED market is expected to recover, enjoying annual growth each year from 2012 to 2015 including double-digit growth in 2013 and 2014 as the lighting market accelerates. The 2012 market is expected to grow 5%, but still remain below 2010 levels. Backlighting is expected to be flat on slower unit growth and price reductions, while lighting is expected to be up 30% as LED lamp penetration jumps as prices continue to fall.

Also read: MOCVD shipments stall, but restart in 2012

Lighting revenues are expected to overtake TV revenues for GaN LEDs in 2012, a year earlier than previously predicted. This is a result of increasing LED lighting demand on lower pricing while reducing the LED outlook in TVs on lower penetration than previously predicted along with the use of low cost direct LED backlights in developing markets.

The low-cost direct LED backlights use around half the LED die area as conventional edge backlights, thanks to reduced brightness and thicker form factors for wide viewing angle. Wide-viewing angle packages further reduced the required LED count. While the adoption of these new low-cost direct-type backlights will narrow the cost differential with CCFL LCD TVs, the thicker form factor and reduced brightness capability will narrow their appeal.

The lighting share of the GaN LED market is expected to surge from 21% in 2011 to 49% in 2016 with lighting LED revenues expected to grow >300% and units expected to grow >1500% over this period.

IMS Research’s Quarterly GaN LED Supply and Demand Report tracks and forecasts MOCVD shipments, LED capacity by manufacturer, LED and MOCVD supply/demand, sapphire supply and demand, sapphire pricing and quarterly notebook, monitor and TV panel shipments by backlight type, size, resolution and refresh rate. New features include separated notebook and tablet LED demand, projector forecasts and LED demand, and much more. For more information, please visit www.ledmarketresearch.com.

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