Designing a Controlled, Reusable Glow Stick with LED Technology for use on Films

We were asked to create an LED-based alternative to traditional chemical glow sticks. The goal was to deliver a solution that could be fully controlled, repeatable, and capable of precise colour tuning—something simply not possible with single-use chemical variants.

This presented an interesting engineering challenge. The primary requirement was to achieve a smooth, even light output around the full circumference of a slim cylindrical form factor. At the same time, the available internal diameter was extremely limited, leaving very little space for both the light source and an effective diffusion system.

Our initial approach involved maximising LED density by integrating as many LED strips as possible within the available circumference. However, it quickly became clear that achieving a truly uniform glow required a more considered optical and mechanical solution.

To solve this, we developed a custom diffuser system, designed in-house and manufactured using 3D printing. This component not only secures the LEDs in position but also plays a critical role in blending the light output into a smooth, consistent emission around the entire surface.

The control system is housed within the handle. Power is provided via a lithium cell, and the system is built around our PX1 technology, enabling reliable wireless control and precise tuning of colour and effects.

The result is a compact, reusable “digital glow stick” that replicates the visual simplicity of a chemical glow stick, while offering the flexibility and control of modern LED technology.

LED Strip LED Controllers DMX RDMX Lumen Lighting control Embedded radio RGBWW control Warm white Cold white LV5 Bi-colour Electronic design PCB design and manufacture RDM Pixel Dimmers Customisable Radio receiver Props Special effects SFX TV lighting Tv and film lighting Stage lighting Innovation Motion control Dali Ethercat Electronic