DIY LED thermal epoxy replacement

[BradB]

I've ran DIY LEDs for around 15 years. LEDs are directly attached to two 24"x48" aluminum sheets that are both the lid of my canopy and function as heat syncs. This almost worked without any additional cooling, but I did add a fan for longevity. Every few years, I remove any dead/dying LEDs and add new ones. I attach LEDs using arctic silver alumina premium ceramic, which was less than $5 when I started. Now it is $25. If I do both panels separately once a year, that was < $10/year and now is $50/year.

I don't know if DIY LEDs still make sense in 2026, but if I continue to use them, I need a cheaper physical attachment and thermal solution. What is everyone using?

I had a scare this morning - half my LEDs didn't turn on, and I suspected my HLG-480H-54 ($180) but it turned out to just be a 20-year old timer that finally failed. But this got me thinking about either going to premade fixtures or getting around to replacing dead/dying LEDs.

 

[Gumbies R Us]

@Troylee

 

[Troylee]

Really not sure what people are using today. Maybe @oreo54 can help ya.. I haven’t done diy led’s in 15 years or so.

 

[oreo54]

I've ran DIY LEDs for around 15 years. LEDs are directly attached to two 24"x48" aluminum sheets that are both the lid of my canopy and function as heat syncs. This almost worked without any additional cooling, but I did add a fan for longevity. Every few years, I remove any dead/dying LEDs and add new ones. I attach LEDs using arctic silver alumina premium ceramic, which was less than $5 when I started. Now it is $25. If I do both panels separately once a year, that was < $10/year and now is $50/year.

I don't know if DIY LEDs still make sense in 2026, but if I continue to use them, I need a cheaper physical attachment and thermal solution. What is everyone using?

I had a scare this morning - half my LEDs didn't turn on, and I suspected my HLG-480H-54 ($180) but it turned out to just be a 20-year old timer that finally failed. But this got me thinking about either going to premade fixtures or getting around to replacing dead/dying LEDs.

Yea just switch to the cheap thermal conductive silicone "glues"
If one digs into the specs you will find there isn't much difference "if" I remember correctly.

If you can find the Tianmu stuff it is dirt cheap and adequate heat transfer.
Dries really slow though. Careful though Tian mu makes numerous products and it isn't always easy to pick the right one. Well it's the ads that make it confusing.


https://www.aliexpress.us/item/3256805126821103.html?gatewayAdapt=glo2usa4itemAdapt

I do not believe "white" is useable. As I said it can be difficult trusting what they say.
No "numbered" silicones are heat transfer types AFAICT.


Actually if you hunt down some thermal pad sheets many actually have a wee bit better transfer characteristics.

There are "superior" products with "superior" products but not always actually superior.
Back to adequate.
"Heatsink Plaster " is the easiest to find.
Thermal Conductivity: >0.671W/m-K
https://www.aliexpress.us/item/3256...|x_object_id:1005010628381926|_p_origin_prod:

Last is JB Weld which has some products that are use-able as thermal transfer adhesives.
I'm not versed in which are and which are not.