We have probably all seen the marketing blurbs on packaging and elsewhere promoting the amazing lifespan of LED lighting solutions. Theoretically you should be able to install a LED bulb in a fixture that used to hold that incandescent lightbulb which had to be replaced annually and have it last a decade or longer. Yet we seem to replace these LED bulbs much more often than that, with them suffering a range of issues. To get to the root cause of this, [The Doubtful Technician] decided to perform an autopsy on a range of dead lightbulbs which he got from a variety of sources and brands.

One lamp is an Amazon-bought one by a seller who seems to have vanished, but was promised over 3 years of constant use. Other than the fun blinding of oneself while testing, this one was easy to diagnose, with a dodgy solder joint on a resistor in a MELF package. The next one from Lowes was very dim, and required popping open with some gentle force, which revealed as likely culprit a shorted SMD resistor. Finally a more substantial (i.e. heavier) bulb was tested which had survived about 7 years in the basement until it and its siblings began to suddenly die. Some might consider this the normal lifespan, but what really failed in them?

The electronics in this last bulb were the most impressive, with a full switch mode power supply (SMPS) that appears to have suffered a failure. Ultimately the pattern with these three bulbs was that while the LEDs themselves were still fine, it were things like the soldering joints and singular components on the LED driver PCB that had failed. Without an easy way to repair these issues, and with merely opening the average LED lightbulb being rather destructive, this seems like another area where what should be easy repairs are in fact not, and more e-waste is created.

It is hard to remember now, but there was a time when electronics were expensive. [Adrian Black] found some 9W (60W equivalent) LED light bulbs at the Dollar Tree (a U.S. store where everything costs a dollar). Naturally, they cost a dollar, and he wanted to see what was inside of them. You can see the resulting video, below.

Apparently where [Adrian] lives there is a subsidy paid to retailers for selling LED lighting, so you may not be able to get the same bulbs at that price. Still, the price of these bulbs has dropped like a rock over the last few years.

It is interesting to see how you cut costs when your volumes go so high. For example, the bulb has two boards in it. They mate with an ingenious slot system cut into the boards themselves and then just solder together. There are 9 LED devices inside, each with three LEDs. The power supply? Just a bridge rectifier and a smoothing capacitor. There’s just not much inside.

When you think about electronic prices in the past, consider that the purchasing power of the dollar keeps dropping, too. A radio might have cost $50 in 1935 and a much better performing radio might cost $10 today. But in 1935, $50 would have been two months of rent or more. So the real comparison isn’t $50 to $10, it is more like $1600 to $10. How can you manufacture a bunch of plastic pieces, 9 LED devices, a capacitor, a bridge rectifier, an IC, two PCBs, and some resistors, put them together, stick them in a printed box, and ship them across the ocean and wind up selling them for a dollar? Keep in mind, too, the store isn’t giving them away, so the actual cost must be less (not counting any subsidy). Amazing.

We’ve talked about scaling designs, although few of us will ever get a design made in the numbers of something like this. Oh, and while we know this isn’t actually a hack, we think you’ll agree this is.

Do you like saving electricity? Who doesn’t!

Do you have a lot of LED light strips lying around, destined for a project that you never quite got around to? We’re guilty!

Do you have an old DC power adapter? Of course you do.

Do you love soldering? Duh.

Do you have a dead fluorescent light bulb sitting around? Maybe…

If so, here’s a quick and silly guide to making your very own LED light bulb! The result is a bit ghetto we admit, but quite functional. Perhaps it could be improved by adding a glass Christmas bobble to make it look a bit more like a regular light bulb. And if you’re ambitious enough you could throw a microprocessor in there and add wireless control to it as well … but let’s be honest, smart LED light bulbs are getting quite affordable these days. But hey, you’ve got to do something for entertainment!