Birth of a Red Light Therapy Panel
A complete walkthrough of how MedLight takes a product from a blank page to a fully certified, shelf-ready device -- every stage, every decision, zero shortcuts.
Phase 01
Concept & Brief
Every panel begins with a conversation. The client brings a market opportunity -- a gap in their product line, a customer pain point, or a clinical application they want to serve. MedLight translates that into a structured product brief.
Client Inputs
- ✦ Target application (pain relief, skin rejuvenation, recovery)
- ✦ End-user profile and treatment environment
- ✦ Budget range and target retail price
- ✦ Regulatory markets (FDA, CE, TGA)
MedLight Outputs
- ✦ Product specification brief
- ✦ Wavelength and irradiance recommendations
- ✦ Form factor options (panel size, mounting)
- ✦ Feasibility and timeline estimate
Key Decision at This Stage
Dual-wavelength (660 nm red + 850 nm NIR) combination panel targeting both surface skin and deep tissue -- a configuration validated across clinical and home-use markets.
Wavelength Spec
660 nm + 850 nm
Phase 02
Engineering Design
The brief becomes a blueprint. Our engineering team designs the optical layout, thermal management system, and structural enclosure -- balancing clinical performance with manufacturability and safety compliance.
Optical Layout Design
LED array density, beam angle, and inter-chip spacing calculated to achieve uniform irradiance across the treatment area. Target: ≥100 mW/cm² at 15 cm.
Thermal Management
Aluminum heat-sink profile and fan-cooling system designed to maintain LED junction temperature below 85°C during continuous 20-minute sessions.
Control & UX Design
Timer controls, power modes, and optional pulse-frequency settings. Enclosure designed for IP40 rating, wall-mount and stand compatibility.
Irradiance Target
≥100 mW/cm²
300
LED chips
60°
Beam angle
IP40
Protection
Phase 03
Prototyping
The first physical unit is built by hand. This is where design intent meets real-world materials -- tolerances are checked, assembly sequences are refined, and the first irradiance measurements are taken.
PCB Assembly & LED Soldering
Hand-assembled prototype PCB with 300 dual-chip LEDs (660 nm + 850 nm). Solder joint inspection under magnification. First power-on verification.
Enclosure Fit Check
3D-printed enclosure shell fitted to the PCB assembly. Thermal paste application, heat-sink mounting, and fan placement confirmed.
First Light & Visual Inspection
Full power-on with visual uniformity check. Dead LEDs, uneven zones, and color consistency reviewed before any measurements.
Client Sample Shipment
One physical prototype shipped to client for hands-on evaluation. Feedback collected on form, feel, controls, and overall impression.
Prototype Milestone
Physical sample shipped to client within 20 days of design approval
Phase 04
Testing & Validation
Data replaces assumptions. Every performance claim is verified with calibrated instruments. Safety and electromagnetic compliance tests are run in parallel with clinical-parameter validation.
Optical Performance
- ✦ Irradiance mapping (9-point grid)
- ✦ Wavelength peak verification (spectrophotometer)
- ✦ Uniformity ratio ≥ 0.85
- ✦ Dose calculation at 10, 15, 20 cm
Safety & EMC
- ✦ Electrical safety (IEC 62368-1)
- ✦ EMC emissions & immunity (EN 55032)
- ✦ Thermal runaway & overheat protection
- ✦ FCC Part 15 / CE RED compliance
Durability & Aging
- ✦ 1,000-hour LED lumen maintenance
- ✦ Thermal cycling (-10°C to +50°C)
- ✦ Vibration & drop test (packaging)
Documentation
- ✦ Full test report issued to client
- ✦ Third-party lab certificates
- ✦ Technical file for market registration
Peak Wavelength
660 ± 5 nm confirmed
CE
Certified
FCC
Part 15
RoHS
Compliant
Phase 05
Mass Production
With prototype approved and test reports signed off, production begins. Every unit passes through a documented quality gate before it leaves the line -- no exceptions.
Production Flow
Quality Standard
AQL 1.5 -- Zero critical defects
500+
Units / month capacity
MOQ
From 50 units · Flexible scaling
Phase 06
Packing
Each unit is packaged to arrive at its destination exactly as it left our facility. From branded retail boxes to reinforced master cartons, every layer of packaging is engineered for protection, presentation, and compliance.
Retail Packaging
- ✦ Custom-printed box with client branding & artwork
- ✦ EPE foam inner mold for device protection
- ✦ Multilingual user manual & quick-start guide
- ✦ Accessories included: power cable, hanging kit, goggles
- ✦ Warranty card & compliance documentation insert
Outer Carton & Labeling
- ✦ Double-wall corrugated master carton
- ✦ Barcode, SKU & destination labeling
- ✦ Fragile / this-side-up handling marks
- ✦ Carton weight & dimensions for freight calculation
- ✦ Packing list & carton count per pallet
Packing Quality Check
Every packed unit undergoes a final visual and weight check before carton sealing. Drop and compression tests are conducted on sample cartons to validate transit protection before bulk packing commences.
Packaging Type
Full Private Label
100%
Units checked
OEM
Custom branding
EPE
Foam protection
Phase 07
Delivery
The product leaves our facility as a complete, branded, shelf-ready unit. We handle export documentation, customs classification, and coordinate with freight forwarders to ensure on-time, damage-free delivery worldwide.
Logistics
- ✦ EXW, FOB, CIF, DDP options
- ✦ Sea freight (bulk) or air (express)
- ✦ HS code classification support
- ✦ Full export documentation package
- ✦ Real-time shipment tracking
Export Documents
- ✦ Commercial invoice & packing list
- ✦ Certificate of origin
- ✦ Bill of lading / airway bill
- ✦ CE / FCC declaration of conformity
- ✦ Insurance certificate on request
After-Sales Support
12-month warranty on all production units. Dedicated account manager for reorder coordination, spare parts supply, and any field issue escalation.
Shipping Reach
Global -- 50+ Countries
End-to-End Timeline
From first conversation to units on your doorstep -- a typical OEM panel project runs 60-100 days.
What You Receive
A complete, certified, shelf-ready product -- not just a device.
Certified Device
CE, FCC, RoHS -- ready for your target market
Private Label
Your brand, your packaging, your identity
Full Documentation
Test reports, technical file, user manuals
After-Sales Support
12-month warranty + dedicated account manager
Ready to Build Your
Own Panel?
Share your concept with our team. We'll review your requirements and respond with a feasibility assessment and indicative timeline within 2 business days.