Steer Clear of Outdated Off-Road Technology With LED Light Bars
Light bars have become the standard nighttime navigation tool for off-roaders. But the invention of more modern lighting systems has made their limitations clear. So, when it’s no longer good enough to have just any off-road LED light bar, how do you know what to look for? Let’s illuminate the best choices for your off-road lighting setup.
The History of Off-Road Lighting From Halogen to LED
In 1898, Columbia became the first manufacturer to introduce the concept of an electric headlamp on automobiles. However, short filament life and limitations in dynamo design hindered widespread adoption until 1912, when Cadillac introduced an integrated electrical ignition and lighting system that would go on to become the foundation of the modern vehicle electrical systems we know today. These early automobile lighting systems relied on incandescent bulbs, a technology that’s still in use but has become less prevalent with the development of more efficient bulbs.
The story of off-road lighting really began with the invention and widespread adoption of halogen lamps. Beginning in the 1970s, these lights served as the primary option for off-road enthusiasts. At the time, KC was the first and foremost manufacturer of off-road lighting, using aircraft landing bulbs in modified steel housings to create the first off-road lights.
These early lights have become known in the off-road community as pods. They offered a powerful light (at least for the time) in a single package that could be installed on off-road vehicles without slowing them down too much.
The Halogen Era & Limitations in Off-Road Applications
With their familiar warm glow, halogen lights set the standard for off-road lighting between 1970 and 1990. However, they struggled in two areas when pitted against difficult conditions: energy inefficiency and a limited lifespan. Halogen lights consume a lot of power, so off-roaders have always been limited in how many they can install. Their delicate filaments are also prone to breakage, especially when exposed to the rigorous demands of off-road terrain.
The Introduction of Xenon/HID Lamps
In the early 1990s, vehicles began appearing with xenon or high-intensity discharge (HID) lamps. HID lamps operate at a lower temperature, giving them a longer lifespan than halogen bulbs. They also produce about twice as many lumens.
On the downside, they’re expensive to replace when they go out. Their power draw spikes upon startup, resulting in a several-second delay before they reach full power. When too many are installed, that initial spike and high power draw can overload a vehicle’s electrical system. At the same time, HID lamps require large reflectors to direct their powerful beams, adding bulk to the body of the light. Their power limitations and cost-prohibitive nature have prevented them from finding mainstream appeal for most off-road applications.
The Transition to LED Technology & Its Advantages
As the quest for more durable, longer-lasting, and efficient lighting options continued, LED (light-emitting diode) technology marked a turning point in the early 2000s. The penetrating, directional light of LEDs dramatically improves nighttime visibility without draining power. This makes them ideal for off-road applications, especially when powering primary or auxiliary lights without the engine running.
Pro tip: Make sure to calculate overall power draw and battery capacity when designing and planning your off-road lighting setup. Otherwise, you could get stuck in the dark with a dead battery.
Advancements in LED Technology for Off-Road Applications
Whether you’re driving off the beaten path, rock crawling, or in the middle of a desert race, being able to see makes or breaks the nighttime off-roading experience. All it takes is one rock or stump you don’t see coming to ruin the ride. It doesn’t matter how bright the moon and stars are—you need reliable sources of light beyond OEM headlamps or foglamps (having a combination of spotlights and floodlights is ideal) to avoid the risk of getting stuck in the dark.
Over the years, off-road LED technology has not only increased brightness but revolutionized the entire concept of vehicle lighting. Many off-road lighting innovations even carry over into road, construction, and emergency vehicle design. Developments in LEDs extend far beyond raw lumen output and the limitations of light bars.
An Overview of LED Advancements
Modern LEDs emit cleaner directional light, meaning the beam is more focused with less scatter. They also offer an unlimited range of color options and temperatures that can be optimized to reduce driver fatigue and improve contrast on the trails. While halogen and HID lamps can be customized to emit a range of colors, the bulb actually remains the same; it’s the lens that determines the colors. LEDs, on the other hand, can be customized so that the diode itself gives off the exact color you want.
Your color options are unlimited with LEDs, but there are two primary options worth considering for off-road lighting:
- Clear/White Light: From racing and rock crawling to casual trail rides, white light is the best general option for maximizing visibility in normal off-roading environments and conditions. It provides the best overall range and color accuracy.
- Amber Light: If you might encounter dusty, snowy, or foggy conditions, many off-roaders prefer to also have the option of amber lighting. It provides better penetration while reducing eye strain since amber light doesn’t reflect off of airborne particles the same way white light does.
While less common, some off-roaders may also require different color options like red (for preserving night vision when stationary) and yellow (for hazard lights). Others may also opt for fun colors like blue, green, pink, or purple as atmospheric lighting that complements their vehicle’s aesthetic when it’s time to kick back at the end of the night.
The Role of LEDs in Powerful Off-Road Lighting
LEDs have become popular among off-road enthusiasts not just for their brightness but for their outstanding energy efficiency. By consuming less power than traditional halogen lamps, they put less strain on the vehicle’s electrical system. The average halogen headlamp consumes about 12.5 amps, while most LED low beams draw anywhere from 1 to 3 amps, meaning an LED headlamp can be up to twelve times more efficient than an equivalent halogen headlamp.
Why does that matter when it comes to off-roading? The extra power draw means you generally can’t power halogen lights for extended periods unless the engine’s idling or you risk draining the battery. LEDs, on the other hand, can run for much longer periods without a problem. Considering the average vehicle battery holds 4,000 to 8,000 watts, the difference between a bulb that draws 12 amps versus one that uses 3 or less can be measured in hours.
Power draw is also a critical factor when designing a reliable off-road lighting setup for climates that may experience extreme temperatures. Whether in the deserts of Dubai or the mountains of Colorado, extreme heat or cold can drastically decrease battery performance. If your lights are already drawing a lot of power, a sudden frost or an extreme spike in heat could be the straw that breaks the camel’s back.
LEDs also provide a higher level of brightness while maintaining a much cooler operating temperature. This contributes to a longer lifespan for both the lights and your vehicle’s battery. In measuring lifespan, the average halogen bulb lasts about 2,000 hours, and you’d be lucky to get 4,000 out of one. Compare that to the average LED with a lifespan of 50,000 hours or more, and even then most won’t go out, they just aren’t as bright. If you run one for eight hours a day, that comes out to more than 17 years before you may start noticing a reduction in overall illumination.
How LEDs Revolutionized Vehicle Lighting for Trucks & Off-Roaders
- Energy Efficiency: LEDs draw up to 12 times less power than equivalent halogen bulbs. Meanwhile, LEDs convert 90% of energy to light, while HIDSs generally fall in the 70-80% range. Among all options available today, LEDs go the farthest at reducing a vehicle’s overall energy consumption and impact on the environment.
- Innovative Designs: Due to LEDs’ compact size, manufacturers can now create sleek, modern designs that emphasize aerodynamics and enhance vehicle style. Halogen lights, however, rely on a bulky bulb that serves as a 360-degree light source and needs to be directed with a lens. Since LEDs are inherently directional light sources, beam control is naturally better and more efficient while taking up less space. High-intensity chips and color chips give designers more luminaire, housing, and lens options without adding bulk.
- Versatility: On top of design flexibility, LED lights can also be manufactured to switch between light types (e.g., color, beam pattern, spotlight, floodlight, etc.) at the touch of a button.
The Latest Trends in Off-Road Vehicle Lighting
The innovation didn’t stop with the switch to LEDs. The off-road lighting industry continues to blaze trails in nighttime illumination. One trend is the integration of lighting control systems and customizations that allow off-roaders to adjust their lighting setup to specific conditions. Another is adaptive lighting technologies that enable drivers to adjust beam patterns with the flip of a switch for optimal visibility. As technology advances, the question isn’t just whether light bars are outdated, but what will drivers look to next for the future of off-road illumination?
Pro insight: The importance of power draw on vehicle design has been highlighted in 2024 as off-roading manufacturers like Jeep (4xe), Hummer (EV SUV and EV Pickup), Polaris (XP Kinetic), Land Rover, and Rivian (R1T) have all entered the market with EVs. Since emerging electric vehicles only have the option of running lights on battery power, every watt counts when designing an off-road lighting setup without draining the vehicle’s range. This factor is even more important in areas where fluctuating temperatures can negatively impact battery performance.
If you want your ride to look the same as everyone else’s, you could get a light bar. Or you could take a look at DuraBrite’s Nano Stacks, available with interchangeable Spotlights and Floodlightsto prepare for anything on the trail.
Beyond LED Light Bars: Modern Alternatives on the Trail
As off-road enthusiasts look ahead, new illumination devices have entered the conversation. LED pods have made a resurgence with customization options that now surpass light bars, bringing a range of advantages that cater to the modern off-roader’s preferences in innovative ways.
The Reinvention of LED Pods
The first off-road lights in the 1970s were what we today call light pods, but since light bars hadn’t been invented yet, nobody really knew the difference. At the time, the closest thing to a light bar was stacking together multiple pods on a roll bar or rack. But because there wasn’t a way to link them together, individual wires had to be run to each pod.
As LED technology became more commonplace in the early 2000s, light bars started appearing as a favorite option for off-roaders. These bars were originally designed to solve the problem of having to install multiple pods side-by-side to form a lighting array. Instead, LED light bars allowed off-roaders the ability to install a single unit that could outperform halogen or HID arrays in efficiency and brightness.
In the years since, light bars have become commonplace enough on vehicles that most states have special legal designations for what’s allowed on public roads and what isn’t.
Despite their status, light bars aren’t without their share of limitations. As you’re designing your off-road lighting system, keep in mind that the limitations of light bars mean they’re not always the best LED light for trucks or off-road vehicles. Available as spotlights and floodlights, LED pods provide a compact, versatile lighting solution that can be mounted almost anywhere on your vehicle. While LED light bars provide a broad wash of light, pods can be optimized and stacked together to pierce through the darkness in a range of conditions. Pods allow for strategic illumination anywhere you need it—a must for the challenges of off-road adventures.
With light bars, you’re limited in location and beam patterns because the light is fixed. With LED pods, you can mix and match placements to achieve the look you want while illuminating the trail ahead, behind, and on the sides. You also can’t customize an LED light bar after you buy it—what you see is what you get. Without the option to later mix and match optics, colors, or beam patterns, you’re stuck with the features you’re given. Light pods have remained an essential option for off-roading due to their ability to tuck them into tighter places and rotate them to the precise point you want to illuminate.
Spotlight pods throw a focused beam far into the distance, with some outperforming bars in sheer range and intensity to help you spot obstacles in the distance when moving quickly. Meanwhile, floodlights cast a broad light over the landscape. They’re particularly effective on the sides or rear of vehicles or when moving slowly over technical terrain. Because they cast a circular cone of light, they tend to provide broader coverage when compared to bars that often lack coverage above or below the light source.
What Each Type of Off-Road Light Does Best
- Pods: Providing primary or auxiliary lighting right where you need it most, LED pods are perfect for tight spots or angles that a central light bar can’t reach. Look for manufacturers that offer pods as spotlights and floodlights, so you have more options for customizing your lighting setup.
- Spotlights: When long-distance visibility is key, spotlights shine supreme. Their tight, powerful beams are ideal for high-speed runs on open trails. LEDs offer the most powerful penetration for spotlights because their design is inherently directional. No energy or space needs to be wasted with the bulky reflectors of halogen and HID lamps.
- Floodlights: Floodlights fill the area surrounding your vehicle with light. While they aren’t designed to extend as far as spotlights, they excel at illuminating everything in the vicinity so you don’t miss anything in the shadows.
- Light Bars: Acceptable for general lighting, light bars broadly spread light to illuminate large areas directly in front of the vehicle when a minimal profile is preferred. However, they’re often underpowered and follow similar design conventions, limiting customization and optical characteristics for modern off-roaders. Many light bars rely on cheap reflectors to direct the light from the LEDs, with much of it lost to scattering. If you’ve seen one LED light bar, you’ve probably seen them all, but if you don’t see a lens on top of each chip, you should stay away.
Evaluating Light Bar Effectiveness for Today’s Off-Road Applications
Are LED light bars outdated, or do they still hold their own when lighting the trail ahead? In terms of general light distribution and visibility, light bars have been a staple for good reason. Their linear design allows for a broad spread of light. This is particularly helpful in open landscapes where detecting hazards on the periphery is crucial. However, off-roaders could run into limitations with light bar setups in these applications:
- Rock Crawling: Illuminating difficult angles and crevices is crucial, and the elevated position of a light bar can provide that much-needed perspective. However, light bars can be difficult to place on the sides or rear of a vehicle, limiting peripheral visibility that’s critical on rock crawls.
- Trail Riding at Night: A light bar may extend how far your vehicle’s lights reach on the trail, but if it’s range you want, LED spotlights are superior. These lights make sure no light or space is wasted with bulky reflectors to direct the beam angle. Non-LED lights may look bright, but much of their light gets lost before it reaches the trail ahead. Even among LEDs, not all units perform equally. This is true even if two light bars look identical on the outside. The best offroad LEDs have a high-power chip to focus beams even farther. Many cheaper units lack this extra punch, an easy corner to cut to mask lower-quality products because it’s cheaper to install 100 low-quality chips that deliver 5,000 lumens than it is to use five high-quality chips to achieve the same lumen count. The final numbers might be the same, but 100 low-power chips will lack the intensity and range of the five high-performance chips. Many low-power LED chips tend to form a bright shallow cone of light, while fewer high-power chips can pierce through the darkness ahead with a focused beam.
- Emergency Situations: When additional light could aid in safety or repairs, light bars can help, but they’re generally difficult to rotate, adjust, or move once installed. If the vehicle can’t move, neither can your light.
The Secret Connection Between Heatsink Design and LED Quality
Looking for an easy way to tell what sets one LED manufacturer apart from the rest? Take a closer look at the heatsink design of their LEDs. Since most LEDs already run at low operating temperatures, many manufacturers cut costs on production with an extruded heatsink that compromises overall performance. They extrude the heatsink and then cut it to length, resulting in fins that are always horizontal. Why’s that a problem? Heat rises, so if you want to maximize thermal efficiency, you need vertical fins.
Once you know what to look for, you won’t be able to unsee it because many LED lightbars have horizontal fins. This results in an increased likelihood of light failure due to overheating or chip malfunctions. You should also look out for manufacturers that underutilize chip potential to cover up issues with heating design while inflating lumen count.
Light bars may have improved spatial awareness and clarity on the trail compared to what was available in the past, but they’re starting to show their age. Not all lights perform equally, and in situations where every lumen counts in demanding off-road conditions, the latest innovations in LED pod design offer a brighter future.
Get the Look & Light You Want With DuraBrite’s Nano Series
Looking to replace your LED light bar? DuraBrite developed the Nano Series just for you. Available as a single LED pod with spotlight, floodlight, and dimming functionality, your Nano Stack can be mixed and matched in many combinations to improve light coverage for virtually any situation. You can stack anywhere from two to nine for a custom array that outperforms light bars in the specific conditions you’re up against. And in places where you can’t fit a full stack, you can almost always fit a Double or Triple Stack instead. And you’ll always have the flexibility to repurpose each individual Pod later on if your lighting needs evolve.
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