Innovating Real-Time CGI Lighting Effects: A Behind-the-Scenes Look at Our Latest Project
Creating realistic shadows in computer-generated imagery (CGI) can be a complex and expensive task during post-production. We met this challenge head on in a recent project, developing a 120mm LED ball, designed to generate real-time light and shadow effects during filming. The innovative solution delivers authentic lighting effects, which assist the CGI team in post-production by enhancing the integration of CGI elements with live-action footage, saving both time and costs.
Click here to watch our YouTube short on how we made the LED Ball.
Our Passion Meets Expertise: The Perfect Match
This project was a perfect fit for our team at EMP Designs, combining our passion for LED projects with our expertise in developing precise control solutions. The challenge was to create a highly customizable, mappable LED sphere, 120mm in diameter, that could produce the brightest light possible while being controlled by a purpose-built controller.
The Design Process: Precision and Innovation
We began by designing the LED ball with individual segments, or slices, populated with LEDs, all centred around a custom-designed PCB hub. The design was meticulously drawn using a 3D drawing package, ensuring that the segment profiles were accurately defined. With the size and shape determined, our team then focused on developing the layout for the electronics, using LED control experience to maximize brightness and performance.
Custom Solutions: From Design to Prototype
On set, the LED ball was suspended inside a clear dome. To achieve perfect central alignment, we designed and manufactured a bespoke connector, created using our 3D drawing software and printed using ASA material on one of our in-house 3D printers. The diversity of our 3D printing capabilities allows us to quickly prototype and ramp up production as needed, ensuring rapid project advancement.
Bespoke Controllers: Tailored to Perfection
To operate the LED ball, a custom controller was designed and manufactured in-house. Our bespoke designs are programmed by our team, collaborating closely with clients and adapting software to meet specific needs. This in-house capability is particularly valuable during the testing phase, enabling us to make quick adjustments to ensure the best results for our clients.
High-Quality Assembly: Combining Precision and Craftsmanship
The assembly of the 120mm LED ball was a blend of automated precision and skilled craftsmanship. Our in-house pick-and-place line efficiently assembled the PCBs, while our soldering team meticulously handled all through-hole soldering. This combination ensured a robust and reliable final product, capable of delivering the high-quality performance expected by our clients.
Bringing It All Together: Testing and Optimization
With the ball and controller ready, we moved on to the testing phase. Using LED mapping software, we achieved precise control and visualization of the LED configurations. This crucial step verified the integration and functionality of the entire system, ensuring that our design would meet the demanding project requirements.
The team at EMP Designs relish a challenge and have the creativity and expertise in developing precise control solutions. Whatever your lighting requirement, or whatever unique effect, prop or product you wish to create, we can work with you to find the best solution.
Please get in contact to chat about any electronic, mechanical or industrial design challenges.
