Table of Contents
Quick Takeaway
Spherical LED Display is a highly customized LED screen, as different customers have different application scenarios. They would order different diameter led spheres and also different pixel pitch requirements. If it is a new size and pixel pitch, then we need to do the design and make tooling from the start.
During all those years of manufacturing Sphere LED Display, We Tepixel now has the LED Sphere screen’s tooling as the chart below, which means if you want to do such pixel pitch and diameter, we do not need to design new tooling for it.
| Application | Sphere LED Display Diameter | Sphere LED Screen Pixel pitch | Sphere Screen Area(m2) | IP Rating | Brightness |
| Indoor | 1m | 1.875mm, 2mm, 2.5mm,3mm | 3.14 | IP40 | 600-800nits |
| 1.2m | 2mm, 3mm | 4.5216 | IP40 | 600-800nits | |
| 1.5m | 1.875mm, 2.5mm, 3mm | 7.065 | IP40 | 600-800nits | |
| 1.8m | 2.5mm | 10.1736 | IP40 | 600-800nits | |
| 2m | 2mm, 2.5mm | 12.56 | IP40 | 600-800nits | |
| 2.2m | 2.5mm | 15.1976 | IP40 | 600-800nits | |
| 2.5m | 2.5mm | 19.625 | IP40 | 600-800nits | |
| 2.8m | 2.5mm | 24.6176 | IP40 | 600-800nits | |
| 3m | 2.5mm | 28.26 | IP40 | 600-800nits | |
| 5m | 2.5mm | 78.5 | IP40 | 600-800nits | |
| Outdoor | 1.5m | 5mm | 7.065 | IP66 | 4500-5500nits |
| 4m | 5mm,6mm | 200.96 | IP66 | 4500-5500nits | |
| 5m | 5mm,6mm | 78.5 | IP66 | 4500-5500nits | |
| 8m | 5mm,6mm | 200.96 | IP66 | 4500-5500nits |
Normally producing an indoor version sphere led display takes around 25-30days, and producing an outdoor version sphere led display takes around 55-65days.
Sphere LED Display Specs confirmation
The first step in making a Sphere LED Display is to confirm the screen’s specs. The major specs are diameter, pixel pitch, and indoor or outdoor use. Outdoor LED Sphere has a totally different LED module and power supplier box structure as it need to withstand rain, wind, UV and high temperature. Outdoor led sphere need to offer at least 4500nit brightness and at least IP65 rated. We Tepixel’s outdoor Sphere led display uses Aluminum LED module casing and mask to make it more durable and better in heat dissipation.
Now the most popular indoor sphere led display is pixel pitch 2.5mm with a diameter of 1.2m.
The most popular Outdoor LED Display is pixel pitch 5mm with a diameter of 1.5m.
Why outdoor version led sphere screen’s pixel pitch start at 5mm?
You might be curious why the outdoor led sphere’s pixel pitch starts at 5mm, the reason is that
1: The outdoor version needs to use outdoor version led lamps, hence the pixel pitch can not be made too small
2: We need to make the LED module front service possible, as this is outdoor use, hence we need to use screw to fix the led module on the sphere frame. and the screen hole has sizes, and we also need strong screw. Hence for outdoor version sphere led display, we recommend to use pixel pitch over 5mm. (indoor version is using magnet)
Designing Sphere LED Display module
After confirming the specs of the sphere led display, then we can start the design. The expansion diagram of the Sphere is as below.
It is composed of a series of curved trapezoids. As we are using soft led module, hence when we do the design, we can make the led module to be trapezoids. and the vertical cross section of the led sphere screen is a regular polygon (the size is the width of the led module), But when viewed from a distance, it can still be recognized as round shape.
How many tooling do we need to make?
When designing the led module, normally the led module has a size limitation of no longer than 380mm, hence all the led modules would have a height less than 380mm. To make the regular polygon more similar to a circle, we need to make the led module width as small as possible (also need to take front maintenance into consideration). And the pixel pitch layout also determines the size of the led module.
Hence the tooling quantities of the led module is try to find the best balance point among pixel pitch, module height, and module width. For example, for our Popular outdoor version led sphere, pixel pitch 5mm, and Diameter 1.5m. It need 7 different tooling to make different size modules. ( Though the top part led module is symmetry to the bottom part led module, but the tooling still is different) And each size led module has 36pcs led modules (The top cap module only need 1 pcs).
Configuring the Sphere LED Module and Aging process
Sphere LED Screen’s led module are trapezoid shape with different size. Hence we need to configure the led module one by one, based on the really pixel layout. Mooncell control system which is specialized in irregular shape led display control, is very user friendly in configuring the led module.Different size module would have its own led board configuration file.
After configured the led board, we can do the screen connection, then the led sphere can be fully controlled and ready to show images or videos.
How to use LED Sphere screen led display
The LED Sphere screen’s display window is a normal rectangle with width:height = 2:1 Ratio. The pixel quantities becomes less when it approaching the top and the bottom. To make the video or image display smoothly, the displaying software would compress the top and bottom resolution to be the same pixel quantities of the sphere, hence it would display smoothly and continuously. In the user’s end, You just upload a 2:1 ratio video, and it can display just fine.
How to do the aging test for the Sphere LED Display screen
For indoor version, the normal aging test takes around 72 hours, we would display full white, red, blue, green, dots, and display preset videos for 72 hours straight.
For outdoor sphere LED Display, we need to do the aging test for 72hours, when everything is stable, we would apply the waterproof layer on the top of the led boards, then we need to do aging test 72 hours again. Then we need to do 2 hours waterproof test. Then it is ready to pack.
How to pack Sphere LED Display
By different sizes it has different package style, normally for diameter less than 1.5m, we would pack the led sphere as a whole within a wooden box, So that it is a plug and play solution. The video controller is also installed inside the frame.
But when the diameter of the Sphere is bigger than 1.5m, We would dismantle the sphere led display into several parts. While the led boards is packed in cartons.
Production Time of the Sphere LED Display
The outdoor led display screen would have a relatively longer production time than indoor version sphere led display.
Indoor sphere led display production time:
It depends on the specs, if we have the tooling, and we also have the stock PCB, then it takes around 20days to produce. If it is new size or pixel pitch, then it takes around 30days to produce. For some pixel pitch such as pixel pitch 2.5mm, diameter 1m, we have stock which can be shipped within 7days.
Outdoor sphere led display production time:
For outdoor sphere led display, if we have tooling, the production time is around 50days, If it is a new size or pixel pitch, then it takes around 60days to produce.
If you want to make sphere LED Display, you can send enquiry to us, and we can give you proposals and the indication production time.
Price of the Sphere LED Display
The price of the Sphere LED Display is depending on the size and pixel pitch. The bigger the diameter and smaller the pixel pitch, the more expensive it would be. Outdoor sphere screens also cost more than indoor sphere screen. If you select a specific LED brand and IC brand, the price can also be higher.
Below is some popular size standard specs sphere led display’s price.
For diameter 1m, pixel pitch 2.5mm, price is around 3500USD
For diameter 1.2m, pixel pitch 2.5mm, price is around 3700USD
For diameter 1.5m, pixel pitch 2.5mm, price is around 9000USD
For more Sphere LED screen’s price, please contact us.
At Tepixel, we not only produce high quality led displays, but also offer appropriate suggestions based on the requirements of your project. What’s more, we would also side by side help you with your project. If you have any questions, welcome to contact us
