Have you considered using solid solder deposits on the PWB? All the needed
paste put down during PWB fab, melted, washed to remove any residues and solder
balls, then hot roll flattened and flux-adhesive applied to the solder
'bricks'.
Next just place components and run thru reflow.
Military cable house doing this very successfully with very fine wires to
attach break out paddle board connectors along the run of the flat ribbon cable.
Old way was to hand solder each minute wire, clean, inspect (rework if
needed). Now a small jig used to place the wires on the solder deposits (on the small
boards), when aligned just apply hot bar and all joints perfectly made. Time
dropped from 3 hrs per paddle board attachment to < 20 min. with much better
quality void-free joints.
A variation of this might work well for your LED attachment.

Bill Kenyon
Global Centre Consulting
P.O. Box 553, Montchanin, DE 19710 USA
Tel: 302.652.4272     Fax: 302.652.5701   Cell: 302.377.4272
email: [log in to unmask]

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