Custom LED Modules
Bespoke LED Module Engineering for Professional Lighting Projects
At GP Trader, we engineer and manufacture custom LED modules tailored to the precise technical requirements of each installation. Our bespoke manufacturing service goes beyond standard catalogue products, allowing full control over every electrical, optical, and mechanical parameter to deliver optimal performance in demanding professional environments.
Precision Electrical Design
Every lighting installation operates under different electrical constraints. We manufacture LED modules at the exact operating voltage your system requires: 12V DC for compact installations with conventional power supplies, 24V DC for extended runs minimising voltage drop, or bespoke configurations for OEM integration projects. Module power output is calibrated—from 1W to over 30W per unit—to achieve the required illuminance levels without oversizing the electrical infrastructure.
Optical Configuration and Beam Control
Precise light distribution is essential in signage, channel letter illumination, and architectural backlighting applications. We configure beam angles ranging from 15° for focused projection to 175° for wide-area diffuse lighting. Our optical solutions include injection-moulded lenses, TIR optics, and custom diffusers that shape the photometric distribution to match each luminaire or sign enclosure specification.
Colour Rendering and Correlated Colour Temperature
We supply modules with CRI > 80 for general commercial use or CRI > 90 where accurate colour reproduction is critical—fashion retail, jewellery displays, gallery lighting. Available CCT options span 2700K warm white through to 6500K daylight, with the ability to specify LED binning tolerances ensuring chromatic consistency across large-scale installations with hundreds of modules.
PCB Form Factor and Thermal Architecture
Modules are manufactured on rigid aluminium-core PCBs for maximum thermal dissipation, or on flexible substrates for installations requiring conformity to curved surfaces. Board dimensions are engineered to fit the available space: from compact 20×20 mm modules for small-format channel letters to 300×300 mm panels for large-format light boxes and stretch ceiling applications.
Professional Cabling and Connector Solutions
We pre-solder power cables to the precise length each installation demands—from 15 cm pigtails to multi-metre runs. Connector options include standard DC barrel (5.5×2.1 mm), JST for compact assemblies, Molex for industrial environments, or custom connectors specified by the client. For public-space installations, lifts, and transport applications, all cabling is available in Low Smoke Zero Halogen (LSZH) specification, fully compliant with European fire safety regulations.
Protection and Regulatory Compliance
Our modules feature surge protection rated up to 6 kV and constant-power driver architecture ensuring stable operation regardless of mains fluctuations. All products comply with IEC 61347, UL 8750, and the RoHS directive, providing documented reliability for professional installations.
Frequently Asked Questions
What is the minimum order quantity for custom LED modules?
MOQ depends on the level of customisation. For cable length and connector modifications, we work from 100 units. For fully custom PCB designs, the minimum is determined on a project basis. Contact our engineering team for an assessment.
What is the lead time for bespoke modules?
Modules with standard modifications (cable length, connectors, voltage) ship within 3–4 weeks. Fully custom PCB designs require 6–8 weeks including prototyping and validation testing.
Can I request validation samples before committing to production?
Yes. We dispatch validation samples so you can verify specifications in your actual application before confirming series production. Samples include photometric and electrical test reports.
Do you offer IP67-rated LED modules?
Yes. We provide IP67-rated modules in compact metal housings for outdoor or humid environments. Resin-potted versions are also available for applications requiring additional environmental protection.
Are the modules compatible with GP Trader power supplies?
All our modules are designed for optimal performance with our constant-current power supplies. We provide specific module-driver pairing recommendations for each project to ensure maximum efficiency and longevity.