1 day ago
Originally published via the Solid State Lighting weekly Postings.
Although growth in U.S. manufacturing is not often highlighted, the solid-state lighting (SSL) industry has been steadily expanding and establishing a strong manufacturing presence domestically. This growth strengthens the U.S.'s position as a leader in SSL technology. SSL originated from U.S. ingenuity and research and development (R&D) and aligns with the global trend toward greater energy efficiency. This creates a valuable opportunity for U.S. companies to increase their role in SSL manufacturing. Occasionally, the Postings highlight SSL companies manufacturing in the U.S. This is not an endorsement but aims to motivate and inspire other U.S. companies to follow suit. The philosophy and activities described here align with the recommendations in the U.S. Department of Energy (DOE) white paper, "Prospects for U.S.-Based Manufacturing in the SSL Industry."
Hubbell Lighting and Control Solutions
Headquartered in Greenville, South Carolina, where more than 500 employees work, Hubbell Lighting is a major manufacturer of LED and conventional luminaires and control solutions. It ranks among the three largest lighting manufacturers based in the U.S. The company offers a portfolio of brands providing lighting and control solutions for nearly every application.
According to Warren Weeks, Director of Innovation and Technology, Hubbell’s SSL journey began in 2008. Before then, the company produced almost no LED lighting products. Today, over two-thirds of its commercial and industrial lighting is LED, and about 55% of its overall products are LED. This growth in LED products is expected to continue. Nearly all of Hubbell’s R&D efforts focus on SSL, which the company views as the future of lighting.
With the rise of LED lighting, Hubbell has transformed from an electrical lighting manufacturer into an electronics manufacturer. It now designs its own printed circuit boards (PCBs), assembles PCB assemblies, develops proprietary and interoperable controls technology, and writes its own firmware and software.
Founded in 1963, Hubbell Lighting has deep roots as an electrical manufacturer, historically relying on mechanical engineers for most luminaire design. Warren notes that before SSL, lamps and ballasts were supplied by different manufacturers, so luminaire design and manufacturing mainly involved mechanical work. With the rapid adoption of SSL, Hubbell has transitioned to electronics manufacturing, employing skilled electronics engineers to design LED circuits, drivers, sensors, and control systems to create fully integrated luminaires. The company has significantly adapted its design, manufacturing, product testing, reliability testing, and quality systems to meet SSL technology demands.
Hubbell works with thousands of suppliers worldwide. Warren explains that the vast majority of its SSL luminaires and safety lighting—including electrical circuits, LED boards, and optical solutions—are designed in the U.S. Electrical components are assembled in Hubbell-owned factories both domestically and abroad, depending on volume and complexity. Custom optics are designed and manufactured by key domestic suppliers. SSL luminaires are manufactured and assembled in Hubbell facilities across the U.S., including locations in Hudson, Wisconsin; Bristol, Pennsylvania; Christiansburg, Virginia; El Dorado, Arkansas; Elgin, Illinois; and Plympton, Massachusetts.
Warren states that Hubbell carefully monitors its cost-effective supply chain. With a substantial amount of domestic manufacturing depending on product mix, the company’s strategy is to balance product complexity and variety without losing focus on customer priorities. This approach keeps manufacturing agile, enabling Hubbell to respond quickly to customer demands.
As the company has evolved with SSL’s transformative impact, employee skill sets have changed dramatically. Beyond the increased need for electronics engineers, Hubbell now employs software engineers who design graphical user interfaces and apps for connected lighting systems. Factory engineers must understand surface-mount technology pick-and-place equipment, reflow ovens, coating systems, and inline electrical testing equipment.
Warren emphasizes that R&D is Hubbell’s primary tool to prepare for changing markets. Its R&D labs in Greenville serve as the nerve center for developing new and improved products quickly and efficiently. This effort targets emerging markets such as connected lighting, human-centric lighting, color-tunable products, and horticultural lighting. General lighting and safety lighting for commercial, industrial, indoor, outdoor, and residential markets remain key focuses.
As the lighting market shifts to SSL technology, Hubbell is among many companies reinforcing U.S. manufacturing and R&D leadership. This not only promotes significant energy savings through more efficient lighting products but also benefits the economy by creating jobs across multiple levels of the supply chain.
