LED Module Technology

How LED chain modules light signs, channel letters and lightboxes evenly, and how to choose the right module, spacing and power supply for your design.

Overview

What is an LED chain module?

An LED chain module is a small, self-contained light source: one or more LEDs mounted on a rigid circuit board with their own current control, sealed in a plastic housing and protected by potting or encapsulation. Modules are joined by flexible wires into chains, so they can be laid out in rows across the back of a sign, inside a channel letter or behind a lightbox face, and powered together from a single low-voltage supply.

Our range runs at 12VDC and covers single-LED mini modules for small letters, multi-LED 2835 modules up to 720lm for large lightboxes, 5050 modules in white and RGB, and an FPC module for minimal spotting. Modules are rated IP65 or IP67, with wide 120° to 175° beam angles, and fix with 3M adhesive tape and a screw hole.

Even, efficient backlighting for signs, letters and lightboxes
Wide-angle optics spread light across the sign face
IP65 and IP67 sealed construction for outdoor signage
Parallel-wired chains that can be cut and joined to suit
Mono-colour white and RGB colour-changing options

Module range at a glance

Voltage: 12VDC
LEDs: 2835 and 5050
LEDs per module: 1 – 6
Colours: White and RGB
Power: 0.2W – 6W per module
Output: up to 720lm per module
Beam angle: 120° – 175°
IP rating: IP65 and IP67
Mounting: 3M tape and screw hole

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The technology

How modules light a sign

Modules are fixed in rows to the back panel of the sign, facing the translucent front face. Each module's wide-angle optic spreads light outwards, and the light from neighbouring modules overlaps before it reaches the face, so the sign glows evenly rather than showing individual bright spots.

The two things that control evenness are depth (the distance from the modules to the face) and spacing (the distance between modules). A deeper box gives the light more room to spread, so modules can be placed further apart. Shallow boxes need closer spacing or wider beam angles.

Every module in a chain is wired in parallel across the 12V supply, so each one receives the same voltage and the chain can be cut or extended between any two modules.

Simplified illustration: LED modules (grey) on the back panel, wired in a chain, with overlapping wide-angle beams lighting the sign face.

Module types

Choosing a module

Match the module to the size and depth of the sign: small modules for narrow letters, high-output modules for large, deep lightboxes.

Type	Our modules	Output & power	Best for
Mini modules	Single 2835 (PWM9607, PWM1210)	0.2 – 0.24W per module	Small and narrow channel letters, shallow returns
2835 multi-LED modules	2, 3, 4 and 6 x 2835 (PWM4417 – PWM6868)	112 – 720lm, 0.72 – 6W per module	Channel letters and lightboxes, from small to large and deep
5050 white modules	3 and 4 x 5050 (PWM6719, PWM5132)	0.72 – 0.96W per module	Channel letters and lightboxes, IP65 or IP67
RGB modules	3 and 4 x 5050 RGB (PWM7118, PWM4237)	0.72 – 1.44W per module	Colour-changing signage, cove and feature lighting
FPC module	2835 on flexible PCB (PWM3322FPC)	86lm, 0.72W per module	Lightboxes 40 – 150mm deep with minimal spotting

Benefits

Advantages of LED modules

Why sign makers choose LED modules over fluorescent tubes and LED strip for backlighting.

Even illumination

Wide-angle optics up to 175° spread light across the face, so fewer modules give a bright, uniform sign without hotspots.

Flexible layout

Wired chains bend around letter shapes and can be spaced to suit any outline, from narrow strokes to large lightboxes.

Built for outdoors

Sealed IP65 and IP67 housings protect the LEDs from moisture and dust in exterior signs.

Low energy, low heat

Efficient 2835 and 5050 LEDs use far less energy than fluorescent tubes, with less heat inside the sign.

Quick to install

3M adhesive tape and a screw hole on every module make fixing fast and secure, with no soldering needed.

White or colour

Mono-colour white modules for classic signs, and RGB modules for colour-changing and dynamic effects.

Design guide

Planning a module layout

Measure the depth from the back panel to the face. Deeper boxes allow wider spacing and fewer modules.
Choose the module for the depth and size: mini modules for narrow letters, high-output modules for large or deep lightboxes.
Lay modules in even rows, keeping spacing between rows similar to spacing along the chain, and keep modules back from the edges to avoid bright borders.
Calculate the power: number of modules x watts per module, plus around 20% margin, to size the 12V supply.
Feed long chains at more than one point to avoid voltage drop and dimmer modules at the far end.
Seal cut wire ends and use outdoor-rated drivers and connectors for exterior signs.

Power supply example

A lightbox using 100 x PWM4417 modules at 0.72W each:

Module load: 100 x 0.72W = 72W
With 20% margin: approx. 86W
Suggested supply: 100W, 12VDC

We supply 12V drivers and controllers to complete your sign:

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12VDC

Safe low voltage

720lm

Max output per module

175°

Widest beam angle

IP67

Highest protection rating

Where LED modules excel

LED modules are the standard light source for illuminated signage.

Channel letters

Face-lit, halo-lit and combination built-up letters.

Lightboxes

Single and double-sided lightboxes, fascias and projecting signs.

Retail signage

Shop fronts, menu boards and illuminated logos.

Forecourt & totems

Pylon signs, totems and forecourt canopies.

Display & exhibition

Backlit graphics, display stands and point-of-sale.

Colour effects

RGB modules for colour-changing signs, coves and feature lighting.

FAQ

LED module questions

An LED chain module is a small, sealed LED light source with one or more LEDs on a rigid PCB, potted or encapsulated for protection. Modules are joined by flexible wires into chains so they can be spaced out across the back of a sign, channel letter or lightbox and powered from a single 12V supply.

Spacing depends on the depth of the lightbox or letter and the beam angle of the module. As a general guide, deeper boxes allow wider spacing because the light has more distance to spread, while shallow boxes need modules closer together or wide-angle modules to avoid hotspots. We can help calculate spacing and module count for your sign.

Multiply the power per module by the number of modules and add a safety margin of around 20%. For example, 100 modules at 0.72W is 72W, so a 100W 12V supply would be suitable. Very long chains should be fed at more than one point to avoid voltage drop.

IP65 modules are protected against dust and water jets, suitable for most sealed outdoor signs. IP67 modules are fully potted and protected against temporary immersion, giving extra protection where condensation or water ingress is likely.

Yes. Module chains are wired in parallel, so the connecting wire can be cut between any two modules to make shorter chains, and chains can be joined to make longer runs. Seal any cut ends to maintain the IP rating.

LED Module Technology