This project focused on the design and fabrication of an ultra-thin flexible printed circuit board (FPC)loaded with addressable pixel LEDs, developed specifically for prop lighting and practical effects in TV and film production.

The PCB is manufactured using polyimide-based flexible substrate with copper conductors and protective coverlay, resulting in a circuit that is exceptionally thin, lightweight, and capable of being bent without mechanical failure. The flexible PCB was engineered to be rolled tightly around a cylindrical form while maintaining its structural integrity. Stitched solder seams along the edges provide mechanical reinforcement, allowing the assembly to hold its shape once formed.

The display consists of a 21 × 8 matrix of individually addressable LEDs mounted directly onto the flexible PCB. The paper-thin construction enables tight bend radii and seamless integration into props where space, weight, and concealment are critical. WS2812-type RGB pixel LEDs were selected, each incorporating its own control circuitry, enabling precise per-pixel colour, brightness, and animation control—ideal for on-camera lighting effects.

Designed with flexibility in mind, the system can be driven by any compatible LED controller capable of outputting the standard WS2812 data protocol making our PX1 range a perfect option. This allows lighting effects to be pre-programmed, triggered live on set, or synchronised with other control systems commonly used in film, television, and immersive installations.

The result is a rollable, flexible LED surface that combines durability, precision, and creative freedom. It is particularly well suited to custom prop lighting, practical effects, set pieces, sculptural lighting elements, and immersive environments, where conventional rigid PCBs or off-the-shelf LED products are unsuitable.