Bespoke LED Lighting Panel for Film & TV Set Applications

We are frequently approached by clients in the film and television industry requiring bespoke lighting panels and custom fixtures for set integration. Whether the requirement is under-table illumination, backlighting scenic elements, or building light directly into props, productions often need solutions that standard off-the-shelf products simply can’t provide.

A common approach is to use LED strip lighting, which is cost-effective in terms of materials. However, for custom installations, strip lighting quickly becomes labour-intensive. Strips must be cut into multiple sections, wired together by hand, mounted carefully to manage heat dissipation, and assembled repeatedly for each new fixture. For higher-volume or time-critical applications, this process becomes both tedious and inefficient. In these cases, custom-designed LED panels offer a far quicker and more reliable solution.

We have produced a wide range of bespoke panels to meet different creative and technical requirements, and one of our most recent projects involved the design of a 632mm diameter circular LED panel for a backlighting application. The panel required RGBWW control, delivering both vibrant colour mixing and high-quality white light output.

Because we already develop and manufacture a wide range of LED fixtures, we hold stock of the necessary LEDs and have an in-house pick-and-place capability. This allowed us to move quickly from concept to production.

Due to the large physical size of the panel, manufacturing it as a single PCB was not practical. Boards of this diameter exceed standard PCB production limits and significantly increase cost. Instead, we engineered the solution as four interlocking quarter sections, each within a manageable size for standard assembly processes. These sections were designed to snap together seamlessly, forming the full 632mm circle once installed.

Clients typically come to us with requirements such as:

• The physical area needing illumination

• Any apertures or clear zones within the panel

• Preferred connection methods for rapid on-set installation

• Control protocol and required light output

With this information, we can design all hardware in-house, manufacture and assemble the panels internally, and deliver a fast, production-ready solution that saves significant time during film set installation.

As with all lighting designed for camera environments, flicker performance is critical. Flicker can be a major issue with LED systems, but all of our controllers operate at high frequencies to ensure compatibility with filming and professional cinematography.

For this project, the panels were paired with our LV5 controller, providing the output and performance required while remaining well suited to the client’s power and control needs.

This project is a great example of how custom LED engineering can simplify on-set workflows while delivering precise, high-quality lighting built around the exact needs of production.