Custom Flex LED Strip Industrial Design
High-Performance Custom Flex LED Strips for Professional Applications
A Flex LED strip is a custom LED module built on a flexible printed circuit board (FPCB). Its ability to bend, curve, and adapt to tight spaces makes it an ideal solution for compact luminaires, long continuous lines of light, embedded lighting in machines or devices, and countless architectural or industrial applications. With lightweight construction and efficient component integration, Flex LED strips enable designs that are impossible with rigid PCBs.
Today, Reel-to-Reel (R2R) Flex manufacturing is transforming LED production in Europe. This advanced process allows continuous fabrication of flexible LED modules up to 100 meters long and 50 centimeters wide, delivering unmatched precision, consistency, and cost-efficiency. It enables high-volume production with superior quality—opening the door to the next generation of flexible lighting systems.
Flex LED strips also offer significant logistical advantages. A single 50-meter reel replaces over 100 individual rigid modules, reducing packaging, storage, handling, and installation time. For large or continuous lighting projects, Flex LED strips minimize wiring, simplify connections, and streamline implementation.
Design for Performance
With more than 20 years of LED design experience, we understand the full range of Flex LED strip applications—from architectural lighting and industrial machines to bioreactors, vehicles, and medical devices. Our industrial design process ensures that every custom Flex LED strip we develop is optimized for performance, reliability, and manufacturability.
During the design process, we evaluate all relevant performance criteria, define the exact specification values, and select the components that best meet them. This results in a highly optimized, manufacturable Flex LED Strip that delivers predictable, long-term performance.
Technical Characteristics We Consider
We evaluate all key technical parameters that define the performance and behavior of a custom Flex LED Strip—including optical output, electrical characteristics, spectrum, lifetime, thermal limits, form factor, circuit type, and protection factor—to ensure the design precisely matches the requirements of your application. Below a non-exhaustive list:
01
LED Luminous Flux
1 lm to 200 lm
03
White Color Temperature
10,000 h to 100,000+ h
05
White Spectrum Quality
CRI 70 to CRI 99
TM-30 metrics
07
Flex LED Strip Voltage
2 V to <270 V
09
Flex LED Strip Length
up to 100 meters (circuit repeatability max 600 mm)
11
Multicolor LED Module
Dual CCT, RGB, RGBW, RGB+W+WW, and more...
02
LED Lifetime
10,000 h to 100,000+ h
04
Color Wavelenght
260 nm to >800 nm (UV, VIS, IR)
06
LED Voltage & Current
1 V to 12 V
10 mA to 700 mA
08
LED Strip Circuit Type
Constant current
Constant voltage
10
Module Zhaga Standard
Zhaga Book 7
12
Waterproof rating
IP65, IP66, IP67, IP68
Sample Custom Flex LED Strip Designs
Starter Design Package
(Flex LED Strips)
Our Starter Design Package covers the major elements required to develop a professional, manufacturable Flex LED Strip. It provides a complete, technically mature foundation that many projects can directly build upon.
from 7,500 €*
Starter Package Includes
1 / Requirements Gathering & Specification Definition
We define all performance targets, project constraints, and industry-specific requirements to ensure the Flex LED strip is designed precisely for its intended application.
2 / LED & Component Selection
We select the optimal LEDs and components using advanced manufacturer tools, binning data, and early-access insights to ensure maximum performance and reliability.
3 / Design for Manufacturing (DFM)
We engineer the flexible PCB materials and layout for electrical, thermal, optical, and mechanical performance. Covers electronic design, mechanical integration, PCB layout, manufacturability optimization, product technical data and design file. 25 Hours of DFM are included in the starter design package.
4 / Design for Certification & Compliance
When required, we design Flex LED strips to meet relevant standards such as Zhaga, safety, EMC, and RoHS.
* Package Limitations
The Starter Design Package covers all major foundations for most Flex LED strip projects, but it does not guarantee final design completion. Additional work may be required depending on complexity.
Extensions can be purchased through:
• Additional Starter Design Package(s), or
• Extra Design for Manufacturing (DFM) hours at 300 € per hour
Terms & Conditions apply.
Deliverables
The design package delivers the Flex LED module technical drawing and specifications, optimized for manufacturing reliability. It provides a proven, production-ready foundation that enables you to advance smoothly to prototyping,
Ready to start your custom Flex LED Strip design?
Contact us today to discuss your project requirements.
