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REEL-TO-REEL LED FLEX TECHNOLOGY
Next-Generation Production of Flexible LED Modules
Precision, Performance & Sustainability – Made in Germany
Reel-to-Reel Flex Technology, the Next-Generation Production of Flexible LED Modules
REEL-TO-REEL LED FLEX TECHNOLOGY
Next-Generation Production of Flexible LED Modules
Precision, Performance & Sustainability – Made in Germany
At LUMISTRIPS, we’ve taken LED module production to the next level with Reel-to-Reel Flex (R2R) manufacturing—an advanced, continuous process that redefines how flexible LED strips are made. With fully automated lines and high-precision engineering, we ensure consistent quality, scalable efficiency, and innovative design possibilities.
This manufacturing method is ideal for producing high volumes of flexible LED modules with exacting accuracy. It minimizes material usage, reduces interconnect points, and enhances product integrity—resulting in LED strips that are more durable, uniform, and cost-efficient.
Why Choose Reel-to-Reel Flex Technology?
Superior Performance & Quality
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Exceptional precision: Consistent alignment and dimensional accuracy
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High repeatability: Uniformity across and within production batches
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Reliable and robust: Fewer breakage points and longer lifespan
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Error reduction: Minimizes sources of failure in the final product
Production Efficiency
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Ideal for high-volume orders with cost-effective scaling
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Shorter lead times through continuous automation
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Flexible module lengths for various applications
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Optimized logistics: Compact storage and reduced handling
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.
Design Freedom
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Enables lightweight, compact, and innovative designs
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Expands application potential in architecture, automotive, and custom luminaires
Sustainability in Focus
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Lower material waste compared to traditional methods
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Environmentally responsible production processes and product development
Certified Quality & Unique Capabilities
We are proud to offer Europe’s only Reel-to-Reel line with plasma direct metallization for flexible PCBs, featuring:
- 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
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Centralized management of all machine systems
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Batch control, spool monitoring, and full traceability
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SMEMA integration for modular machine start/stop
02 – Unroll
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Handles roll weights up to 150 kg
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Quick-change units for seamless substrate roll swaps
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Pneumatic mechanisms for secure material handling
03 – Label
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XY gantry system with high-resolution inkjet printing
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Custom markings: barcodes, serial numbers, logos, and more
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±10 μm repeatability with camera-guided positioning
04 – Solder paste printing
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Market-leading DEK printer with HawkEye inspection
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Precise solder paste application for optimal joints
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Cycle time of just a few seconds with stencil auto-feed
05 – Equipment
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Dual ASM SIPLACE Di2 and TX2 machines
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Up to 72,000 components/hour
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Vision system and full traceability of each placement
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Feeder tech for quick changeovers and accuracy
06 – Infrared soldering
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Rehm VXC2450 convection system with zone profiling
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ViCON software for detailed process control
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Reliable soldering, even with lead-free materials
07 – Automatic visual inspection
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Detects missing, offset, or incorrect components
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Light-up testing with custom adapters
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4-way projection for high-resolution analysis
08 – Precision cutting
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XY programmable cutter with ±50 μm repeatability
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Supports both linear and free-form cuts
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Ultrasonic blade for clean results and long tool life
09 – Roll up
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Automated roll-up with splice, cut, and tension control
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Accommodates individual strips and full-width rolls
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Continuous monitoring and quality control throughout
LUMISTRIPS: 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, LUMISTRIPS is ready to deliver—with technology that’s truly ahead of its time.
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