The LV966 project originated from work within the film and television industry, specifically the need to control large numbers of individual LEDs used in science-fiction sets and props. Typical applications include spaceship consoles, control panels, and set dressing elements where dozens — sometimes hundreds — of LEDs are required to create the impression of active, responsive technology.

On these sets, lighting effects often need to be precisely programmed, repeatable, and synchronised with camera motion passes or visual effects shots. Random or manually wired lighting solutions are not sufficient; designers need full control over intensity, timing, and patterns, with the ability to replay identical sequences reliably.

The Challenge

Large console panels can easily contain hundreds of LEDs, and in some cases significantly more. Traditionally, each LED requires individual wiring back to a controller, along with its own current-limiting resistor. This leads to:

• Extremely high wiring complexity

• Increased build time and labour costs

• Greater potential for wiring errors

• Difficult maintenance and reconfiguration on set

The challenge was to provide high channel count LED control while dramatically reducing wiring effort and setup time.

The Solution

The LV966 was designed as a high-density LED controller providing:

• 96 low-current LED channels for individual indicator and pixel control

• 6 high-current channels for LED strip, backlighting, or edge lighting

• Integrated current-limiting resistors on all low-current channels

• DMX control with optional radio DMX capability

• A compact, serviceable, production-ready enclosure

By integrating the resistors directly into the controller, the need to manually fit up to 96 individual resistors at the LED end is completely removed. This shifts complexity away from the panel build and into the controller, saving significant time and reducing wiring errors.

IDC Ribbon Connectivity

To further reduce wiring intensity, the LV966 uses IDC ribbon cable connectors, a proven and widely available connector system commonly used in computing and industrial applications.

Each IDC connector allows 16 LED channels to be terminated in a single crimp, meaning:

• One ribbon cable can carry 16 LED channels

• Multiple ribbons can be used for LED groups in different areas of a panel

• Panels with large LED counts can be wired quickly and cleanly

In this configuration, all LED positives are tied together and powered locally from the controller’s regulated 5V supply, while the negative connections are switched through the IDC ribbons. This approach dramatically reduces cable preparation time and overall wiring cost and volume.

Flexibility on Set

The LV966 was designed to be a universal, portable controller. Panels can be quickly disconnected and reconnected, allowing a single controller to be moved between multiple set pieces when they are not being filmed simultaneously. This flexibility is particularly valuable in studio environments where space, time, and equipment availability are limited.

Advanced DMX Addressing

Many set builds require both grouped and individual control. For example:

• Shared backlighting across multiple panels

• Individually controlled indicator LEDs or “pixels”

To support this, the LV966 software separates the control banks:

• The 6 high-current channels can be assigned to one DMX start address

• The 96 low-current channels can be assigned to a different DMX address

This allows designers to control global lighting elements and detailed pixel effects independently within a single DMX universe.

Design and Development

The LV966 builds on previous controller designs, incorporating feedback from real-world use on set. Development included:

• Full electronic redesign to remove obsolete components

• New firmware and menu system aligned with other recent products

• A consistent front-panel interface using a custom membrane

• Mechanical design to fit a modified standard enclosure

Only one prototype iteration was required, thanks to extensive upfront planning around interface layout, connector placement, enclosure selection, and manufacturability.

In-House Manufacturing

With the exception of PCB fabrication and membrane printing, the LV966 is produced entirely in-house:

• Circuit and schematic design

• PCB layout and assembly

• Pick-and-place and selective soldering

• Automated optical inspection

• Firmware programming and testing

• Enclosure custom machining

• Final assembly, packaging, and stock preparation

This approach ensures high repeatability, quality control, and long-term support.

Outcome

The LV966 delivers a practical, high-channel-count LED control solution tailored specifically for film, television, and set construction environments. By dramatically reducing wiring complexity while maintaining precise, repeatable control, it enables faster builds, cleaner panels, and more flexible on-set workflows.