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Efficient manufacturing for

flexible LED modules –

Made in Germany

REEL-TO-REEL

FLEX-PRODUCTION

More reliable, cheaper, faster

Reel-to-Reel Flex technology is revolutionizing the production of flexible LED modules and opening up exciting opportunities for the lighting industry. This innovative method enables the continuous production of LED modules on flexible carrier materials. By using high-precision roller processes, large quantities of LED modules can be produced efficiently and cost-effectively. Studies show that reel-to-reel flex processes not only enable improved production speed, but can also increase the quality and reliability of the LED modules.

Various advantages of R2R production

Cost savings in high-volume applications

  • Lower costs for large quantities through efficient production

  • Less material consumption, fewer connections

  • Savings on assembly and labor costs

Flexibility / design advantages

  • New innovative shapes and designs possible

  • No commitment to rigid geometries

  • New areas of application

  • Lower weight, lower height

More environmentally friendly

The roll-to-roll process reduces material consumption and waste, contributing to greener production and promoting sustainability.

Higher product quality and reliability

  • Higher stability and robustness (no breakage points)

  • Exact alignment, positioning or dimensional accuracy

  • High repeatability: Free of irregularities, uniform distances

  • Reduction of potential sources of error

  • Less susceptible to performance loss, longer service life

  • Exact reproducibility of the LED modules (within a production batch and across different batches)

Better processing/automation

  • Easier application using robots and machines

  • Easier assembly, no additional tools

  • Reduced lead times, increased productivity and consistent quality

  • Efficient production

  • Advantages with changing product lengths

  • Low storage requirements, optimized logistics and inventory management

CONTACT

Enquire about your project!

Do not hesitate to contact our LED module expert.

​

Daniel Görike – Key Account Manager –

Tel. +49 7471 96014 – 73

E-Mail dg@leds.de

​

VIEW

Trends and future developments in the area of ​​reel-to-reel flex

The use of reel-to-reel flex technology for the production of flexible LED modules is not only an emerging trend in the lighting industry, but we are seeing a shift from rigid modules to reel-to-reel by many of our customers. Goods. This trend is motivated by a holistic approach to cost optimization and increasing product quality. Customers recognize advantages in the increased stability and robustness of the LED modules, which has a positive effect on quality and reliability.

Large selection from stock

Our standard portfolio includes a variety of flexible LED modules for almost every requirement!

CERTIFIED

ISO certified quality

We deliver certified quality. LUMITRONIX® is a partner you can rely on. Our quality management is certified according to DIN EN ISO 9001 and covers all areas – from product development to customer service. As a responsible company, LUMITRONIX® also has certified occupational safety according to ISO 45001.

Save energy and conserve resources

It's often the little things that add up to make a big difference. In addition to our certified environmental management, responsible use of our resources is very important to us. We therefore try to act sustainably, save energy and avoid waste every day through various measures.

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UNIQUE IN EUROPE

  • Ultra-modern machine park

  • 600 mm image length with endless repeatability

  • 150 mm – 500 mm substrate widths

  • Thicknesses from 10 μm – 150 μm

  • Traceability thanks to laser-engraved barcode

  • Maximum process reliability through full automation

Characteristics of our production:

THE LINE IN DETAIL

State-of-the-art machinery for the highest quality

The series processing of the flexible circuit boards takes place in-house on our new high-end production line. The new flex strip park is able to assemble the plasma-metallized base boards using the reel-to-reel process. Thanks to state-of-the-art machines and high processing speeds, production can be realized on a large industrial scale.

01 – Line Control

With Line Control we have full control over the line and the production process and can react immediately in the event of a problem.

​

  • Control of transport systems and systems

  • Start/stop the individual machines via SMEMA

  • Handling of production batches and individual processing fields

  • Monitoring of spoolers and buffers

  • Control of the winding and unwinding units

  • Data tracing packages for traceability

02 – Unroll

  • Roll weight up to 150kg

  • Diameter of roller holder 76 and 153mm

  • Quick change unit for substrate roll holder

  • Joining unit for leading belt Roller knife for optimal substrate separation

  • Pneumatic hold-down mechanism

03 – Label

  • Freely programmable XY gantry system

  • Inkjet printing system for marking all customer-specific requests such as: barcodes, batch numbers, customer item numbers, logos, counters, etc.

  • Precise construction with linear motors and digital encoder system Camera for precise positioning Repeatability < 10μm

04 – Solder paste printing

Over half of all defective solder joints are due to paste printing. Our fully automatic solder paste printer from the market leader DEK is the basis for our high process reliability. ​

 

  • Reliable printing process for an optimal soldering result

  • Cycle time of just a few seconds

  • Automatic stencil feeding and positioning with drip protection

  • HawkEye paste inspection accurate to a few μm

  • Squeegee pressure control of the squeegee head

  • Cyclone high-speed underside cleaning Highest printing accuracy of 20 μm at 6 sigma

05 – Equipment

  • Special transport unit

  • High assembly speed of 52,500 components/h (according to IPC)

  • Large range of components (01005 – 27x27mm at maximum Component height of 8.5mm)

  • High accuracy of 34 μm at 3 sigma Total capacity of 120 x 8mm spaces

06 – Infrared soldering

  • Infrared heating elements

  • Positionable soldering chamber for different image lengths

  • Zone temperature measurement and control with separately controllable heating elements

  • Soldering process monitoring and control according to standardized reflow profiles

  • Soldering fume extraction

07 – Automatic visual inspection

The integrated functional test detects errors in series production. Missing or incorrectly equipped components, twisted and offset components, as well as non-existent or contaminated components are reliably detected.

 

  • Light-up tests using customer-specific contact adapters

  • Material tensioning unit for optimal substrate positioning

  • Best possible measurement coverage at high resolution

  • Ongoing process monitoring

08 – Precision cutting

  • Freely programmable XY cutting system

  • Precise construction with linear motors

  • Repeatability ±50 μm

  • Linear cutting and free-form cutting possible

  • Ultrasound-stimulated cutting blade for long service life and the best possible cutting results

  • For all common films and substrates Camera for precise positioning of the cutting head

09 – Roll up

  • Cut and splice function

  • Setup trolley for quick roll changes

  • Acceptance of individual strips on individual rolls or substrate widths up to 500 mm

  • Joining unit for trailing belt

  • Roller knife for optimal substrate separation

  • Pneumatic hold-down mechanism

  • Material tensioning unit for optimal substrate positioning

  • Best possible measurement coverage at high resolution

  • Ongoing process monitoring

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