Because of the energy efficiency and high light output of LED lights and the long life of the bulbs, these lights are not only an easy option for the users but have also become a must in the larger interest of the society for preventing environmental pollution. Keeping in mind the increasing demand for these lights, manufacturers are using the best in material and technology for the making of LED lightbar.

Though much of the basic design of an LED lightbar continues to be the same, many modifications are being made in light bars to improve its quality.

Extruded aluminum has always been used for the body of an LED lightbar. Aluminum and other metals are extruded to get the desired cross section for an object. For this, a die is drawn through the metal, is some cases when it is hot and in other cases when it is cold. This produces the necessary pattern within and gives good surface finish to the metal. In many a modern LED lightbar, while the body continues to be extruded aluminum, die-cast aluminum is used for the ends of the body. In die-casting, the metal is injected under high pressure into the mold. Die-casting gives better dimensional accuracy so that in most instances machining is not necessary after that. Besides, the aluminum casings of modern LED lightbar will have a built-in heat sink that will keep the lights cool.

The beam styles available in light bars also have diversified a lot over the years. There is euro style beam, which typically produces a strong beam, and pencil style beam, which is intense and narrow. Then there is the cornering beam which is appropriate when the vehicle is turning, then flood beam, and also the type of beam suitable for fog conditions. The die-cast housing and mounting options of the new generation LED lightbar keeps the beam steady even when the vehicle is moving on uneven terrains. Pencil beams are useful on long and straight highways, but less in other conditions. Some light bars now also have auto-dimming facility where the sensor attached to it can sense the outside light levels and increase or decrease the light output accordingly.

With every next generation model of LED lightbar, manufacturers give a lot of importance to making it low profile, increasing its light output, and making it more energy efficient. In the xmitter light bars used for both on road and off road purposes, a 12 LED lightbar can give a light output of 3600 lumens which is more than what a high intensity discharge light of 35 watts can produce. For this much output, the light bar draws only 4 amps of current.

Several mounting choices are also a characteristic of modern LED lightbar. There are magnetic mounting options, L brackets, adhesive straps, suction cups, tubing mounts, and roll cage mounts and within some mounts there could be further color and material options. Black powder coated steel, polished or anodized chrome, steel, and rubber mounts are available for an LED lightbar. With temporary mounts, more than one type of mount can be stored in the vehicle for convenient mounting on different parts. Permanent mounting kits for replacements are also available for LED lightbar with which temporary mounts can be converted into permanent mounts in vehicles that need them on a permanent basis.