Brand:

• Martin

Affected Products:

• MAC Ultra Performance
• MAC Ultra Wash

Summary:

Reports were received of MAC Ultra Performance and MAC Ultra Wash fixtures showing one or two failed LEDs within the light engine.  The issue was primarily noticeable at low output levels and was reported across more than 50 fixtures in the field.  Engineering conducted a comprehensive investigation involving failure analysis, supplier engagement, thermal and lifetime testing, X-ray inspections, and PCB construction reviews.

The investigation identified micro-cracks in some failed LEDs, likely resulting from manufacturing-related stress during PCB assembly.  While PCB dielectric thickness was investigated as a potential contributing factor, testing could not reproduce the failures under controlled conditions.  Engineering ultimately concluded that the light engine design remains robust, with isolated LED failures having minimal impact on overall fixture performance and most affected units remaining within specified output degradation limits.

Sample photos, under microscope: 

Troubleshooting:

• Failure analysis identified micro-cracks in affected LEDs as the failure mode.
• Investigation suggested the cracks were most likely introduced during the manufacturing process, creating latent weaknesses that later resulted in isolated LED failures.
• PCB construction was reviewed after discovering dielectric thickness significantly exceeded the original specification; however, testing was unable to conclusively reproduce the field failures.
• Extensive thermal, mechanical, electrical, and long-term lifetime testing did not reveal any systemic reliability concerns with the MAC Ultra light engine design.
• Engineering concluded that the issue represents rare, isolated premature LED failures rather than a broader product design defect.
• No product redesign or field corrective action was implemented as a result of this investigation.
• Units exhibiting failed LEDs should be managed through the standard service process, with light engine replacement performed when required.