REEL-TO-REEL LED FLEX TECHNOLOGY
Next-Generation Production of Flexible LED Modules
Precision, Performance & Sustainability – Made in Germany
Flex-Production
Better, more reliable, cheaper, faster
At LUMISTRIPS, we’ve advanced flexible LED module production with Reel-to-Reel (R2R) Flex manufacturing—a fully automated, high-precision process that ensures consistent quality and scalable efficiency.
Ideal for high-volume production, R2R minimizes material use, reduces interconnects, and enhances durability—delivering uniform, cost-effective LED strips with superior reliability.
100m Flexible Sheets
The R2R innovative method enables the continuous production of LED strips on flexible carrier materials. By using high-precision roller processes, large quantities of LED modules can be produced efficiently and cost-effectively. One production batch can have an extraordinary length of 100 meters and width of 50 centimeters. Studies show that reel-to-reel flex processes enable improved production speed, and increase the quality and reliability of the LED systems.
Advantages of Reel-to-Reel Flex
1
Reliable
Our manufacturing process ensures reliable, high-volume production through continuous fabrication on flexible substrates, minimizing manual intervention and process steps. Optimized for large-scale orders and custom formats, it delivers precise, repeatable results with minimal variance.
2
Superior Quality
LED strips manufactured with R2R technology offer superior quality and reliability, featuring enhanced stability and durability of the flexible PCB. With reduced lead times and consistent production quality, they ensure higher productivity and longer service life with minimal performance loss.
3
Design Freedom
Manufacturing of LED strip in long, flexible sheets enables lightweight, compact, and innovative LED designs, supporting flexible module lengths, curved or non-traditional layouts. R2R technology is expanding application possibilities in architecture, automotive, and custom luminaires.
4
Environmentally Friendly
Reel-to-Rell Flex manufacturing reduces material consumption and waste, contributing to greener production and sustainability.
R2R Manufacturing Lot Explained
Our R2R manufacturing process ensures reliable, high-volume production through continuous fabrication on flexible substrates, minimizing manual intervention and process steps. Optimized for large-scale orders and custom formats, R2R is the best fit for your project if the quantity requirement can be adapted to match our production lot.
R2R Flex Production Input
The circuit image of the 100 x 10 mm LED module (example 1) is replicated to uniformly cover a 50,000 x 50 mm reel of flexible PCB. The reel is loaded in machine that starts the R2R manufacturing process. This is reel is the production full lot.
R2R Flex Production Output
From the 50,000 x 500 mm reel of flexible PCB the manufacturing output is 25,000 flexible LED modules (example 1), in 50 reels with a width of 10 mm each. When integrating into lighting fixtures, the reels of flexible LED modules can be divided every 100 mm with a simple cutting tool, to obtain the initial module size or multiples of it.
Design, Quote, Order -all Online
We simplify LED design with our specialized online process, allowing you to quickly receive a quote or place an order for your custom Flexible LED strip, in configurations up to 50 meters in length and 40 mm in width. User-friendly design options that adhere to Zhaga Book 7 Standard are also available.
Unique In Europe
Our R2R manufacturing features plasma direct metallization for flexible PCBs, supports various materials like PI, PET, and paper, and enables LED strip production in widths from 150 mm to 500 mm and lengths up to 100 meters.
State-of-the-art machinery
for the highest performance
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
Automated DEK solder paste printer with HawkEye inspection ensures accurate deposition for long-lasting, defect-free joints.
05 – Placement
ASM SIPLACE Di2 and TX2 machines deliver blazing speed and ultra-precise LED and component 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 – Inspection
Advanced visual inspection systems detect missing, offset, or misaligned components and provide high-resolution inspection for continuous quality assurance.
08 – Cutting
XY precision 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.
Get a Quote for Custom R2R LEDs
LUMISTRIPS
Hechingen, Germany
Kwun Tong, Hong Kong
Ramnicu Valcea, Romania
+40.729.850.710