UV Curing worked example

UV LED Array Power Density at 99% thermal and aging derate factor: a worked example

What does the result look like when thermal and aging derate factor reaches 99%? The full calculation is worked below with real intermediate numbers. Use it during LED array sourcing or retrofit sizing to compare quotes from different vendors, or to scale a known-good design to a new product width.

The inputs for this scenario

  • Total UV optical power of the LED array: 180 W (UV) (unchanged)
  • Effective emitting length of the array: 12 in (unchanged)
  • Thermal and aging derate factor: 99 % (raised for this scenario; the documented default is 90)

Working through the calculation

  • Applying the documented formula (Nameplate density = UV optical power ÷ array length (W/in)) to the inputs above produces each figure below.
  • At this operating point the engine returns 14.85 W / in for effective w/in at part, the number this scenario is built around.
  • At this operating point the engine returns 15 W / in (UV optical) for raw density.
  • At this operating point the engine returns 178 pieces for effective quantity.
  • At this operating point the engine returns 12 in for array effective length.

How this compares with the baseline

  • Against the tool's baseline example, where thermal and aging derate factor sits at 90% and the headline result is 13.5 W / in, this scenario comes in 10% above the baseline at 14.85 W / in.
  • A figure at this level is achievable when thermal and aging derate factor is genuinely sustained, not just peaked for a shift. It gives linear power density along the array, not peak irradiance (W/cm²) at the working distance — actual cure also depends on emitter-to-part gap, focusing optics, and beam spread, which this does not model.

Results at a glance

  • Effective W/in at part: 14.85 W / in (headline result)
  • Raw density: 15 W / in (UV optical)
  • Effective quantity: 178 pieces
  • Array effective length: 12 in

Run it with your numbers

  • Every input above is editable in the live UV LED Array Power Density calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.