We’re often asked to develop LED spheres in a wide range of sizes, each with its own mechanical and optical challenges. As part of our ongoing R&D, we regularly explore new construction methods to improve consistency, scalability, and visual performance.

Building on the success of our 100mm LED sphere, we expanded the concept to create a larger, more complex “world” structure. The design uses a series of precision PCB slices that dock into a central internal ring, allowing the sphere to be assembled in sections while maintaining accurate alignment.

This modular approach ensures consistent LED spacing across the entire surface—resulting in a uniform, high-quality visual output. It also makes the system more repeatable and adaptable for different sizes and configurations.

Each LED is individually controllable, enabling full pixel mapping across the sphere. This allows animations, colour transitions, and dynamic effects to be displayed seamlessly over the entire surface, transforming the structure into a fully programmable 3D display.

As an added feature, the sphere is designed to rotate, introducing motion as another creative layer and enhancing its visual impact in an installation environment.