Custom LED Module + Lens
Industrial Design
High-Performance Custom LED Modules for Professional Applications
An LED module combined with an optical system—such as a lens, reflector, linear optic, or lens array—forms a complete light engine capable of delivering precise beam control, uniformity, intensity, and light distribution tailored to the project’s requirements. These optical systems transform raw LED output into functional, application-ready illumination used in professional lighting fixtures, industrial equipment, medical devices, signage, vehicles, research systems, and many specialized fields.
Design for Performance
With more than 20 years of LED system design experience, we engineer LED modules with integrated optics that achieve the performance your application needs: controlled beam angles, high uniformity, minimized glare, increased peak intensity, and optimized optical efficiency. By combining deep LED knowledge with expertise in optical component selection, thermal management, and PCB design, we deliver custom light engines that outperform generic solutions.
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 light engine 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 LED module—including optical output, electrical characteristics, spectrum, lifetime, thermal limits, form factor, circuit type, and LED technology—to ensure the design precisely matches the requirements of your application. Below a non-exhaustive list:
01
LED Luminous Flux
1 lm to 50,000 lm
03
LED Optics
Reflectors, Lenses, Linear lenses, Lens arrays
05
White Spectrum Quality
CRI 70 to CRI 99
TM-30 metrics
07
LED Module Voltage
2 V to <270 V
09
LED Module Length
10 mm to 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
White Color Temperature
10,000 h to 100,000+ h
06
LED Voltage & Current
1 V to 72 V
10 mA to 5000 mA
08
LED Module Circuit Type
Constant current
Constant voltage
10
Module Zhaga Standard
Zhaga Books: 2, 3, 4, 6, 8, 10, 11, 15, 19
12
Color Wavelenght
260 nm to >800 nm (UV, VIS, IR)
Sample Custom LED Module Designs
Starter Design Package
(LED Modules)
Our Starter Design Package provides all the essential engineering needed to develop a complete LED module with an integrated optical system. It is 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 LED module and optic system are designed precisely for the intended application.
2 / LED & Component Selection
We select the optimal LEDs and supporting components using advanced tools, binning data, and manufacturer insights to ensure the best possible performance.
3 / Lens Selection
We evaluate and select the most suitable lens or optical system—lens, reflector, linear lens, or array—from leading manufacturers, using photometric data to match your performance goals.
4 / Design for Manufacturing (DFM)
We engineer the PCB materials and layout for electrical, thermal, and optical performance, perform a full DFM review, and prepare the technical documentation and design file needed for reliable production. 25 Hours of DFM are included in the starter design package.
5 / Design for Certification & Compliance
When required, we design the LED module to meet relevant standards such as Zhaga, safety, EMC, and RoHS, ensuring compliance for your target market.
* Package Limitations
The Starter Design Package provides a complete foundation for most LED module + lens projects but does not guarantee final design completion. Additional work may be required depending on complexity. Extensions can be purchased through additional Starter Design Packages or extra DFM hours at 300 € per hour.
Terms & Conditions apply.
Deliverables
The design package delivers the 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 LED module design?
Contact us today to discuss your project requirements.
