LED headlight bulbs have gained significant popularity among drivers due to their superior brightness, extended lifespan, and exceptional light beam patterns.
Despite the many advantages that LED headlights offer, you many concern about such questions like: how hot do LED headlight bulb get? Can LED headlight bulbs get overheat and harm my car? Will LED headlight bulb melt my dust cover?
As LED technology continues to evolve, it is crucial to address these concerns and understand the cooling technologies incorporated into modern LED headlight bulbs. Properly designed LED headlights should include features like advanced cooling systems and heat dissipation materials to prevent overheating.
In this article, we will answer two of the most frequently asked questions: Do car LED lights really run hotter than halogen lights? Will car LED headlights melt my dust cover? Finally, you will also find out the factors affecting the temperature of LED headlight bulbs, and how to choose a right bulb for your car.
The Cooling Technologies of LED Headlight Bulb
The heat of LED headlights mainly comes from the heat generated by the LED light source. Almost all the electricity consumed by the LED light source can be converted into light and heat.
Therefore, heat dissipation will directly impact the performance, longevity, and safety of LED headlight bulb. Currently, there are three main heat dissipation technologies for LED headlights on the market:
1. Aluminum Heat Sink
Most LED headlight bulbs use 6063 aluminum heat sink for heat dissipation. Under the same volume and weight, aluminum has better thermal conductivity than copper.
It can transfer heat to the surface of the heat sink faster and improve heat dissipation efficiency. Additionally, aluminum heat sinks are lighter in weight and less expensive to manufacture.
Pros: Lightweight; Cost-effective; Easier to shape; High durability
Cons: Lower thermal conductivity than copper
2. Copper Braid Belt
LED headlight bulb with copper braid belt is considered as passive heat dissipation. For LED headlight bulb with copper strip, you will see that they always have several long copper strips, which are usually nickel-plated copper wire braids. When the LED bulb is working, the heat is eventually transferred to the copper strip, and these strips dissipate the heat into the air.
Pros: Saving space, easy installation
Cons: Poor heat dissipation, Can not use in high output LED headlight bulb
3. Fan Cooling
It is common to find that LED headlights to use fan as active heat dissipation. The advantage of active cooling is that the heat dissipation efficiency is higher than passive cooling. Therefore, LED headlight bulbs that incorporate fan for cooling can be designed with a higher lumen rating .
Pros: Can achieve higher power level. Better cooling ensures longer lifespan
Cons: Often more expensive, bigger heat sink, may cause noise
4. Copper Heat Pipe
Heat pipes are composed of copper pipes, capillary structures and working liquids. One end of the heat pipe is the evaporation zone, the other end is the condensation zone, and the middle part is the insulation section.
Inside the copper tube, a working fluid absorbs heat from the LED chips, causing it to vaporize. The vapor then moves toward cooler areas of the tube, where it condenses and releases the absorbed heat. This process efficiently transfers heat from high-temperature zones to low-temperature areas, keeping the LED bulb cool and preventing overheating.
Pros: Compact design of the bulb, more efficient heat dissipation, enhance lifespan
Cons: Higher Cost, Increase the overall weight of the bulb
LED VS. Halogen Headlight Bulb: Which Runs Hotter?
Now that you understand the key cooling methods used in LED headlight bulbs, it’s important to note that LED headlight bulbs often combine multiple cooling technologies for effective heat dissipation. With such advanced cooling mechanisms in place, you might wonder: can LED headlight bulbs still get hotter than halogen bulbs, or do they stay cooler despite their bright output? Let’s check!
1. Preparation
Testing Equipment
- High Temperature Chamber: Simulate Extreme Usage Environments
- Multiplex Temperature Recorder: record temperature data from various locations or devices at the same time.


Testing Products
- NAOEVO GT6 H4 LED Headlight Bulb (55W 6600LM)
- OEM H4 Halogen Headlight Bulb (55W 1000LM)


2. Testing Purpose
- Compare the temperatures of the original halogen bulb and the LED headlight under simulated extreme usage conditions to determine if the LED headlight’s temperature becomes higher than original halogen when covered the dust cover. Will LED headlight bulb melt the dust cover?
- If the headlight assembly can handle the heat, can the LED headlight bulb itself endure the high temperatures?
3. Testing Process
- Install Original Halogen Bulb Into Headlight Assembly

- Cover the Dust Cap

- Install NAOEVO GT6 LED Headlight Bulb

- Cover the Dust Cap

4. Testing Results
LED vs Halogen Temperature Test With Headlight Assembly
Install the GT6 LED bulb and OEM halogen bulb into the headlight assembly, turn on the power, cover them with the dust cover, and place these two assembly into the high-temperature test chamber. Test both at the same temperature for two hours.
After testing for 2 hours, it was measured that the temperature of the GT6 LED headlight bulb inside the assembly was 103.1°C, while the temperature of halogen headlight assembly was 131.3 °C.

LED vs Halogen Temperature Test of Individual Bulbs
What is the temperature difference between the GT6 LED headlight bulb and the halogen bulb? Does the halogen bulb still run hotter than the LED bulb?
We tested the GT6 LED bulb and a halogen bulb by running them for 2 hours under the same conditions. The results showed that the temperature of the halogen bulb’s filament reached 360°C, while a point farther from the filament measured 132.3°C, slightly higher than the 131.3°C inside the headlight assembly.
In contrast, the GT6 LED bulb recorded a temperature of 88.63°C at the light source, 63.06°C at the heat sink, and 68.84°C at the Canbus driver.


5. Conclusion From The Above Tests:
1. Performance in High Temperature Chamber
In a high temperature oven at 88.7 degrees testing temperature, the LED headlight assembly operates at a significantly lower temperature (103.1 °C) compared to the halogen assembly (131 °C). Both of them worked normally, and the dust cover is still intact.
2. Normal Driving Conditions
In regular driving conditions, the LED headlight assembly remains cooler (50-60°C) compared to the halogen bulb assembly (75-90°C). This indicates that LEDs are more efficient at managing heat in everyday use.
3. Bulb Temperature
The filament of the halogen bulb reaches a much higher temperature (360°C) compared to the LED bulb (88.63°C), showcasing the advantage of LEDs in terms of heat dissipation and possibly longer lifespan.
Therefore, when installing LED headlights with the original car dust cover, the temperature inside the LED headlight assembly is much lower than that of halogen headlight assembly.
When installing LED headlights with the original car dust cover, the temperature won’t get high enough to damage your dust cover, so there’s no need to worry about the heat from LED headlights harming your car’s electrical system.
Why LED Headlight Bulb Runs Cooler Than Halogen?


[Halogen VS LED Headlight: Working Principle]
Halogen lamps is a type of thermal light source, rely on the high temperature of the filament for their light emission mechanism. As the filament’s temperature rises, the color temperature and luminous flux of the halogen lamp also increase accordingly. This method of light emission means that halogen lamps generate a significant amount of heat during the lighting process.
In contrast, the light emission principle of LED headlight bulb is entirely different. LED is a solid-state lighting device, and its light is produced by activating electrons in the semiconductor material through an electric current, resulting in the emission of light energy. This process does not require a high-temperature environment; in fact, excessive heat can damage the structure and function of the LED lamp. LED headlight bulbs.
In short, LED headlight bulbs are more sensitive to heat, so they need to be designed with good cooling systems to keep them from getting too hot. This helps LED bulbs run cooler than halogen bulbs, which improves their performance and makes them last longer.
Successful Cases of Installing NAOEVO GT6 LED Bulb
1. 2016-2017 Honda Accord

[2016-2017 Honda Accord]

The compact design of the GT6 LED headlight bulb leaves enough room for the dust cap. Its hollow heat sink and high-speed 8500 RPM fan improve heat dissipation, keeping the bulb at a safe temperature. This prevents overheating and light dimming, ensuring a longer lifespan and a more comfortable driving experience.
2. 2018-2019 NISSAN SYLPHY


The image above shows the GT6 LED bulb installed in the headlight housing of a 2018-2019 NISSAN SYLPHY. The GT6 LED headlight bulb has a compact heat sink and is almost the same length as a halogen bulb. This makes it easy to install in vehicles with limited headlight space. You don’t have to worry about it not fitting or about heat dissipation issues after using the original dust cover.
3. 2019 Geely Emgrand GS

[2019 Geely Emgrand GS]


The GT6 LED headlight bulb features 6 high-intensity 55-mil flip chips, delivering an impressive output of 110W and 13,200 lumens per set. This powerful performance provides a wide and clear light beam pattern, significantly enhancing visibility on the road.
Despite its brightness, the GT6 is designed with a precise cutoff to minimize glare for oncoming traffic, ensuring safer driving conditions for everyone. Whether you’re driving at night or in low-visibility conditions, the GT6 LED bulb offers exceptional clarity without compromising safety for other drivers.
Conclusion
In conclusion, while LED headlight bulbs generate less heat than traditional halogen bulbs, proper installation and adequate cooling are essential to prevent potential overheating. With advanced heat management systems like fans and heat sinks, high-quality LED bulbs are designed to stay within safe temperature limits, protecting your car’s electrical system and components. As long as you choose well-designed LED headlights, you don’t need to worry about them overheating or causing damage to your vehicle.