REEL-TO-REEL LED FLEX TECHNOLOGY
High-Tech Manufacturing for Flexible LED Modules – Made in Germany
Smarter. Faster. More Sustainable.
High-Tech Manufacturing for Flexible LED Modules – Made in Germany
REEL-TO-REEL LED FLEX TECHNOLOGY
Next-Generation Production of Flexible LED Modules
Precision, Performance & Sustainability – Made in Germany
At LEDRISE, we’re setting new standards in the production of flexible LED strips with Reel-to-Reel Flex (R2R) technology—a cutting-edge, fully automated manufacturing process that delivers unmatched efficiency, reliability, and scalability.
This high-precision process enables continuous production on flexible substrates, allowing for the cost-effective manufacturing of large quantities of high-quality LED modules. With significantly reduced material waste and fewer interconnections, R2R lowers costs and enhances the overall durability, uniformity, and lifespan of flexible LED strips.
Advantages of Reel-to-Reel Flex production
Reliable High-Volume Manufacturing
- Continuous production on flexible substrates
- Reduced manual intervention and fewer process steps
- Optimized for large-scale orders and custom formats
- Accurate and repeatable results with minimal variance
Stronger Design Flexibility
- Enables lighter, slimmer lighting systems
- Supports curved, free-form, or non-traditional layouts
- Opens up new application areas in automotive, medical, architectural, and industrial lighting
ENVIRONMENTALLY FRIENDLY
The Reel-to-Rell Flex manufacturing process reduces material consumption and waste, contributing to greener production and sustainability.
MORE ENVIRONMENTALLY FRIENDLY
The Reel-to-Rell Flex manufacturing process reduces material consumption and waste, contributing to greener production and sustainability.
Superior LED strip quality and reliability
- Higher stability and robustness of flexible LED PCB
- Reduced lead times, increased productivity and consistent quality
- Less susceptible to performance loss, longer service life
Sustainable by Design
- Lower resource consumption and waste
- Efficient energy use across the entire process
- Supports long-term environmental and economic goals
Certified Quality You Can Trust
Our Reel-to-Reel Flex production line is one of a kind in Europe, offering:
- Plasma direct metallization for robust, flexible PCBs
- Substrate widths from 150 mm to 500 mm
- Production lengths up to 100 meters
- up to 600 mm image repeat length with seamless transitions
- Full traceability with laser-engraved barcode tracking
All processes are carried out in our ISO 9001, 14001, and 45001 certified manufacturing center in Germany—ensuring consistent quality, environmental responsibility, and workplace safety.
UNIQUE IN EUROPE
- Plasma direct metallization manufacturing for flexible PCBs
- Multiple options of PCB materials: PI, PET, Paper
- 150 mm – 500 mm substrate widths
- Up to 100 meters LED strip length
STATE-OF-THE-ART MACHINERY
- Ultra-modern machine park
- High processing speeds
- Maximum process reliability through full automation
- Traceability thanks to laser-engraved barcode
UNIQUE IN EUROPE
- Plasma direct metallization manufacturing for flexible PCBs
- Multiple options of PCB materials: PI, PET, Paper
- 150 mm – 500 mm substrate widths
- Up to 100 meters LED strip length
STATE-OF-THE-ART MACHINERY
- Ultra-modern machine park
- High processing speeds
- Maximum process reliability through full automation
- Traceability thanks to laser-engraved barcode
State-of-the-art machinery for the highest quality
At the forefront of innovation in LED manufacturing, our new Reel-to-Reel Flex production line represents a leap forward in both scale and precision. This fully automated system enables the high-speed, continuous production of flexible LED modules with exceptional quality, traceability, and reliability—ideal for demanding industrial applications. Below, we present an overview of the key features, processes, and technological capabilities that make our line unique in Europe.
01 – Line Control
Total oversight of the production line with real-time response to system status, machine interaction via SMEMA, and complete batch traceability.
02 – Unroll
Handles heavy rolls (up to 150 kg), features fast-change units, roller knives for precision separation, and pneumatic hold-down for stable processing.
03 – Label
Custom marking of each PCB with batch IDs, part numbers, or barcodes using a precise gantry and inkjet system with <10 μm repeatability.
04 – Solder paste printing
Automated DEK solder paste printer with HawkEye inspection ensures accurate deposition for long-lasting, defect-free joints.
05 – Equipment
ASM SIPLACE Di2 and TX2 machines deliver blazing speed and ultra-precise placement, with full traceability and feeder tech for minimal downtime.
06 – Infrared soldering
Rehm’s Vision X convection soldering ensures optimal heating profiles, efficient cooling, and high process reliability—even with lead-free solder.
07 – Automatic visual inspection
Advanced AOI systems detect missing, offset, or misaligned components and provide high-resolution inspection for continuous quality assurance.
08 – Precision cutting
XY cutting with ultrasonic blades for straight and free-form edges—ideal for various film and substrate types, with repeat accuracy of ±50 μm.
09 – Roll up
Streamlined roll-up station with splice and cut capabilities, tension control, and continuous process monitoring for perfect final product handling.
LEDRISE: Your Partner in Future-Ready LED Manufacturing
Our Reel-to-Reel Flex line delivers German-engineered performance with a commitment to quality, innovation, and sustainability. Whether you need consistent long-term supply, custom lighting solutions, or high-volume production, LEDRISE is ready to deliver—with technology that’s truly ahead of its time.
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