DESIGN ONE · LED TECHNOLOGY
Custom LED module design and manufacturing
We develop LED modules around the shape of the luminaire and the lighting effect you want to achieve. We match high-power LEDs, optics and custom-designed circuit boards to the space available inside the luminaire.
From the outset, we consider light distribution, heat dissipation, driver selection and access for servicing together.
The technology images are concept illustrations.
Light distribution
High-power LED modules with LEDiL optics
The right optic directs light where it is needed. Matching the lens to the LED lets us tailor the width, shape and direction of the beam to the surface being lit.
Targeted and even illumination
Depending on the application, we can specify narrow, wide, elliptical or asymmetric light distributions. Highlighting a detail, washing a wall and covering a large area each call for different optics.
Matching the LED, optic and housing
We position and mount the lens to suit the LED and the luminaire. The LED and optic pairing, together with the way it is installed, determines the resulting light distribution.
Custom electronics
Custom LED circuit board design and manufacturing
The printed circuit board, or PCB, provides the mechanical and electrical foundation of the LED module. We design the board outline, LED layout and connector positions to suit the space available in the luminaire.
Shaped to fit the luminaire
The board can be linear, circular or shaped to fit a specific luminaire. We account for the optics, mounting points and available space.
Electrical design and driver selection
We match the LED circuit and electrical load to the selected driver. Power supply, wiring and dimming requirements are defined during design.
Mechanical design
Module components and heat dissipation
Mechanical design plays a direct role in how an LED module performs. We design the board, heat sink, optic holder and housing to fit together and simplify assembly.
Fit and mounting
We adapt brackets, spacers and housing components to the module geometry. These details affect both the direction of the light and how the module is assembled.
Thermal design for the operating load
We size the cooling solution for the LED load, luminaire dimensions and installation environment. Good thermal contact and sufficient cooling area help keep operating temperatures within the intended range.
We can coordinate the module’s mechanical design with luminaire manufacturing.
Assembly and servicing
Quick connectors and service access
We choose connection points to suit how the system is installed and used. A suitable quick connector makes the module easier to fit and disconnect and helps keep the wiring tidy inside the luminaire.
Connections sized for the load
Connector type, electrical rating, wire selection and routing are matched to the module’s operating conditions.
Designed for access and replacement
During design, we agree how the module and driver will be accessed. Replacing a module also depends on how the luminaire housing is built and assembled.
Light quality and controls
White, tunable white and RGBW LED modules
We select the light source to suit how the space will be used and the atmosphere you want to create. Light quality, dimming and control options are specified together.
White light and colour rendering
We specify colour temperature and colour rendering requirements to suit the materials and the application. Luminous flux and colour rendering are confirmed for the selected LED and operating conditions.
Tunable white and DALI DT8
Two white channels and a suitable driver allow the colour temperature to be adjusted. For DALI DT8, we check which colour control mode the driver supports.
RGBW and DMX lighting scenes
RGBW modules add a dedicated white channel to the red, green and blue channels. With suitable DMX controls, the system can run lighting scenes, address individual elements and create dynamic effects.
A driver matched to the module
DALI or DMX connectivity is provided by a compatible driver or controller. We assess dimming, flicker and building automation integration across the complete system.
From concept to production
LED module development from concept to installation
Whether it is a design luminaire, façade lighting or a custom architectural detail, we start by defining what the module needs to achieve. We develop the lighting effect and installation requirements alongside the technical design.
1. Requirements and technical concept
We confirm the dimensions, light distribution, colour temperature, quantity and control requirements. These guide the LED selection, optics and board layout.
2. Prototyping and testing
A prototype lets us check fit, lighting performance and thermal behaviour. We agree any changes before the design is approved.
3. Manufacturing and integration
We manufacture the modules to the approved design and provide the installation and control information agreed for the project.
For the Zsolnay façade at Tópark, we developed luminaires with a custom light distribution and individually controlled RGBW LED modules. The project page shows the installation and explains how it was achieved.
Explore the Tópark Zsolnay façade project
We also offer lighting design.
Common questions
Frequently asked questions about custom LED modules
What is an LED module?
An LED module is a light source assembly mounted on a board. It may include optics, a connector and other components. It requires a compatible driver and adequate heat dissipation.
How does an LED module differ from an LED strip?
The custom modules on this page typically use a rigid circuit board with an LED layout and optics tailored to the luminaire. LED strips are usually flexible and made up of repeating segments, which suit different installation requirements.
Can you make an LED board to custom dimensions?
Yes. We can tailor the board’s shape, dimensions and component layout to the installation and technical requirements. We discuss the options at the start of the project.
Are all LED modules rated for 12 or 24 volts?
An LED module can use constant-voltage or constant-current drive. Choose a power supply or LED driver that matches the module’s electrical specifications.
Can an LED module be controlled with DALI or DMX?
Yes, with a compatible driver or controller. The features available depend on the module’s channels and the controller’s capabilities.
Can an LED module be used outdoors?
For outdoor use, the complete luminaire, connections and wiring must be suitable for the environment. A bare PCB requires protection from the weather.
How much does a custom LED module cost?
The price depends on the development work, LEDs and optics, mechanical design and quantity. We prepare a quote once the technical requirements are clear.
What information do you need to prepare a quote?
A drawing or installation dimensions, the lighting effect, light colour, control requirements, operating environment, quantity and target date help us define the scope.
Project enquiries
Tell us about your LED module project
Send us a drawing or the available installation dimensions, along with the lighting effect you want and the estimated quantity. If you already know the control requirements or target date, include those too.