Forge Europa > Designers and Manufacturers of LED Custom Designs


Custom Products From our production facility in the Zhejiang province of China. We can supply a variety of custom sub assemblies, examples include: LED arrays (e.g. brake, traffic light or decorative lighting clusters) Custom LED dot matrix or seven segment displays Custom LED assemblies (e.g. LED bulb replacements) LEDs pre-wired onto looms LED light bars and lighting strips This BSI ISO 9001 approved factory is equipped with cutting edge manufacturing equipment including a dedicated lead-free reflow soldering line. We can custom build sub-assemblies to your precise specification, allowing you take advantage of our extensive experience of handling LED products. Our European design centre in the UK can assist with product design and development giving you the best of both worlds-low cost manufacturing and local design support.

Typical Custom Development Process

Dot Matrix, Alphanumeric or 7 Segment Displays

If you are looking to create a unique look or perhaps to reduce the assembly costs of your moving message display, Forge Europa can supply a tailor made LED dot matrix display to your specifications.

Custom versions can be based either on a tile approach or by using an array of LEDs on a PCB. There are a number of design features that can be altered to create a unique product. Examples include physical size, dot configuration and pitch, viewing angle, emitter colour, pin spacing, electrical configuration, and display format (number of rows and columns). Forge Europa's flexible approach, short development lead time and low tooling costs makes the use of a custom product achievable for low to medium volume production runs (10k+ range).

By taking advantage of the latest technological developments it is possible to enhance the product's performance and reliability. Low cost manufacturing takes place in a purpose built factory in China and is carefully controlled to ensure batch consistency and repeatability to guarantee a high quality appearance of the finished display.

LED Backlights for LCD Displays

A well designed backlight has a considerable influence on the performance of the LCD. It can dramatically improve the readability, contrast and clarity of the display as well as enhancing the overall aesthetic appearance of the equipment it is mounted in.

Forge Europa can offer a custom designed edge or direct illuminated LED backlights. Using LEDs has a number of advantages. They offer distinct and vivid colours, long life (50 000hours) and the opportunity for precise dimming or intensity control. Power consumption is very low and can be further reduced by using PWM drive circuits.

Particular emphasis is placed on achieving excellent uniformity of both colour and intensity. These backlights are ideal for small to medium size LCDs which are typically used in instrumentation and portable equipment.

As well as single colour devices, backlights can be built with red, green and blue LEDs to give a wide colour gamut or customised colours for example to match a corporate logo or image.


LED Lighting Assemblies The use of high power LEDs demands a more rigorous design and manufacturing approach than conventional through hole devices. It is important to consider the thermal design if you want to guarantee long term reliability and ensure that the LED is not operating above its maximum junction temperature. Careful assessment of the optical system is also required to ensure the lowest number of LEDs is used to keep component costs to a minimum. Forge Europa has extensive experience in the application of LEDs and has recently developed a number of standard assemblies using power LEDs known as aLED®. These aLEDs consist of a high power LED mounted onto a thermally optimised substrate complete with a connector or solder pads.
These can be readily customised to suit the requirements of particular light fittings or applications. This takes the headaches of thermal design away from the luminaire manufacturer and gives them an easy to use sub-assembly. When multiple units are combined into one fitting Forge Europa can also measure the junction temperature of the LEDs to verify that the design is working within its recommended parameters. These are ideal for backlighting and smaller lighting fixtures (e.g. MR16). As well as standard products customised solutions to meet specific applications can readily be provided.

LED Sub-Assemblies

We can manufacture a range of LED sub assemblies to your design specification. This can be large arrays or clusters of LEDs mounted onto a PCB in a wide range of shapes and sizes, LEDs mounted onto flex circuits for lighting strips or simple assemblies such as an LED with flying leads.

Custom Products

Typical Custom Development Process

Dot Matrix, Alphanumeric or 7 Segment Displays

LED Backlights for LCD Displays

LED Lighting Assemblies

LED Sub-Assemblies