From Inquiry to Shipment: Custom Dual-Color LED Sheet Project for Stone Backlighting

Key Takeaways

• Solution: Dual-color LED Sheet system for large-area translucent stone backlighting.
• Result: Achieved uniform illumination with zero visible hotspots at <30mm installation depth.
• System Scale: Controlled 100 LED Sheet modules across 3 zones using Casambi + PWM dimming.
• Efficiency: Delivered from design approval to shipment in 12 working day.
• Architecture: Single power supply + single controller per zone after load optimization.

Introduction

This is a custom LED Sheet lighting project developed for a translucent stone backlighting application in Northern Europe, covering the full process from initial inquiry to final shipment, including system engineering, material testing, and production delivery.

LED Sheet Light is a modular, cuttable planar light source designed for uniform surface illumination in architectural backlighting applications, offering high light diffusion performance, reduced hotspot visibility, and flexible installation for irregular structures.

In stone backlighting systems, the primary challenge is not brightness but achieving uniform light distribution through materials with varying optical diffusion properties, while maintaining stable performance under constraints such as installation depth, power distribution, and dimming compatibility.

This case study demonstrates how a dual-color LED Sheet system was engineered to meet these requirements and deliver a stable, controllable, and installation-ready lighting solution.

Project Overview: A Nordic Design Studio’s Custom Stone Backlighting Request

This project came from a Nordic architectural design studio looking for a dual-color LED Sheet lighting solution for a custom translucent stone installation. The objective was to create soft and uniform backlighting while maintaining flexible brightness and color temperature adjustment for different ambient scenes.

Unlike conventional decorative lighting applications, stone backlighting places much higher demands on light diffusion, hotspot control, installation depth, and overall system stability. Even high-power lighting systems may fail to deliver a premium visual effect if uneven illumination or visible LED hotspots appear behind the stone surface.

Compared with traditional LED strips or rigid LED panels, LED Sheet systems offer greater layout flexibility, distributed lighting capability, and better integration for irregular architectural structures. For a more detailed comparison between LED Sheet and conventional LED panel solutions, please refer to LED Sheet vs LED Panel: Key Differences, Applications, and How to Choose.

Why LED Sheet Was Selected Instead of Traditional LED Strip

For projects that require large-area uniform illumination, LED Sheet systems are generally more effective than traditional LED strip layouts. A more detailed technical comparison between the two solutions can be found in LED Sheet Light vs. LED Strip Light: What’s the Difference?.

For this project, the client required both uniform stone illumination and simplified installation flexibility, making dual-color LED Sheet Light a more suitable solution than conventional LED strip layouts.

Project Snapshot

After reviewing the installation dimensions provided by the client, the LED Sheet layout and quantity were calculated based on the lighting coverage requirement of each installation area.

• Area A: 30 pcs (Casambi CCT Control)
• Area B: 30 pcs (Casambi CCT Control)
• Area C: 25 pcs (PWM CCT Control)

To simplify future maintenance and reduce potential downtime risk, an additional 15 spare modules were also recommended during the quotation stage.

At the early communication stage, the client had limited experience with LED Sheet systems and was unfamiliar with cascading connections and controller configuration. To simplify understanding, we provided real installation photos, wiring references, and previous project examples to explain the overall system structure and installation logic.

Tunable White LED Sheets

Size ( LxH ): 250mmx 250mm/ 490mmx245mm
LED type: 2835 SMD
LED quantity: 200PCS/484PCS
Working voltage: DC 24V
Power: 16W / 40W
Color temperature adjustable range: 2700K – 6500K
Luminous flux:1600lm/m/3800lm/m
Color rendering index: >90Ra
Minimum cutting length: 25mmx25 mm/22.3 mm x22.3mm
Dimmable: YES
Beam angle: 120°

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What Information Is Needed Before Starting a Stone Backlighting Project?

Before system design and quotation, several key project details were confirmed with the client to ensure the LED Sheet solution could meet both lighting performance and installation requirements.

For architectural stone backlighting applications, factors such as stone diffusion performance, installation depth, dimming requirements, and power distribution can directly affect the final lighting result.

Key Project Information Confirmed Before Engineering Design

In this project, the client initially focused mainly on lighting appearance and dimming flexibility. However, after reviewing the actual installation conditions and stone material characteristics, the engineering focus gradually shifted toward power optimization, cascading stability, and simplified installation structure.

This early-stage requirement confirmation helped reduce potential installation risks and made the later system optimization process significantly more efficient.

Engineering Solution: System Design & Power Optimization

At this stage, the project was no longer simply about selecting compatible components. The main challenge became balancing system stability, installation simplicity, and electrical load limitations within a single integrated solution.

Dimming System Strategy

The client required flexible dimming capability for future architectural applications. However, due to the distributed load structure of LED Sheet systems, not all dimming protocols can maintain stable performance under large-area operation.

After evaluation, two compatible solutions were selected:

• Casambi wireless dimming system
• PWM dual-color dimming system

The final selection focused on long-term stability, smooth dimming performance, and compatibility with continuous distributed loads.

Controller selection was based not only on dimming functionality, but also on load capacity, dual-color compatibility, cascading stability, and long-distance signal reliability.

For this project, wireless Casambi control provided flexible smart dimming capability for architectural applications, while the PWM dual-color controller offered stable CCT adjustment and simplified integration with the LED Sheet power structure.

This combination helped balance user control experience, installation simplicity, and long-term operational stability.

System Verification & Connection Testing

To help the client better understand the system structure and verify real operating performance, multiple connection and dimming tests were completed before final confirmation.

Both Casambi wireless dimming and PWM CCT control configurations were tested using actual LED Sheet modules, including cascading connection verification, brightness adjustment, and dual-color dimming performance.

The testing process also verified controller loading capability and long-distance cascading stability under continuous operation conditions.

Real testing photos, wiring diagrams, and operation videos were provided to the client to simplify installation understanding and reduce uncertainty during project implementation.

Installation Constraint

One of the client’s key requirements was: Each lighting zone must operate with only one power supply and one controller.

In conventional LED Sheet systems, power is typically distributed through multiple injection points to maintain stable current flow. A single-power architecture significantly increases the complexity of load balancing and thermal control.

Without proper optimization, uneven current distribution and overheating can easily occur in large-area lighting applications.

To simplify installation, the client also expected each controller to manage the entire lighting zone instead of splitting the system into multiple control sections.

Based on the final power optimization result, each controller was configured to manage approximately 25–30 LED Sheet modules within a single zone.

The cascading connection structure was also redesigned to maintain stable current distribution and dimming performance across the entire installation area.

This approach streamlined the overall system layout while maintaining reliable signal transmission and stable operation across long cascading connections.

Zone Configuration Summary

Real Material Testing Changed the Design Direction

Instead of relying only on theoretical calculations, we tested the system using the actual stone material provided by the client.

Unlike standard decorative lighting materials, translucent stone reacts differently depending on material density, thickness, texture, and internal diffusion characteristics. Because of this, installation depth and light diffusion performance had to be evaluated together during the testing stage.

The testing process focused on several key factors:

• Light diffusion performance of the stone
• Hotspot visibility at different installation depths
• Brightness uniformity under dual-color operation
• System load under real application conditions

The result showed that the stone itself provided strong light diffusion capability, allowing the system to achieve soft and uniform illumination at a lower brightness level than initially estimated.

This also made it possible to optimize the overall system load and redesign the power architecture without affecting lighting uniformity or dimming performance.

Optimized System Outcome

After system optimization, the final solution achieved:

• One power supply per zone
• One controller per zone
• Stable operation under optimized load
• Uniform hotspot-free stone backlighting
• Simplified on-site installation process

Testing, Production & Quality Assurance

After final approval, the project moved into production and system validation to ensure full compliance with the engineered design.

All LED Sheet modules were manufactured within 12 working days. Before assembly, all key components—including power supplies and dimming controllers—were cross-checked for system compatibility.

Each lighting zone was delivered as a pre-configured system kit with matched wiring, controllers, and settings to ensure plug-and-play installation on site.

Before shipment, full system verification was completed, including power stability testing, dimming response check, and continuous dual-color operation under real load conditions.

Photometric validation (IES and integrating sphere testing) was also conducted to confirm consistent light output after system optimization.

After passing all tests, the system was released for packaging and labeled by installation zones for efficient on-site deployment.

Final Result

• Verified system stability under full load
• Consistent dimming and color performance
• Uniform optical output across all zones
• Installation-ready delivery structure

FAQ

Conclusion

This project demonstrated how a properly engineered LED Sheet system can deliver stable architectural backlighting performance while simplifying installation and maintaining reliable dimming and power control.

By combining real material testing, optimized electrical architecture, and compatible dimming control, the final solution successfully achieved stable visual performance for the architectural stone application.

If you have similar stone backlighting or custom LED Sheet projects, feel free to discuss your requirements with us.

SignliteLED supports architectural lighting projects with in-house manufacturing, experienced engineering & R&D teams, strong customization capability, and extensive project experience.

RGBW LED sheet lights

Size(LxW): 250mmx250mm/490mmx250mm
LED type: 5050 RGBW 4 In 1 SMD LEDs
LED quantity: 150LEDs/288LEDs
Working voltage: DC 24V
Power: 24 W/48W
Emitting color: RGB + warm white ( 3000K ), RGB + natural white ( 4000K ), RGB + cool white ( 6000K )
Light Efficiency: 90LM/W
Minimum cutting length: 50mmx50mm/20.4mm x122.5mm
Beam angle: 120°
Dimmable: YES

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Addressable LED Sheets

Size(LxW): 250mmx250mm
LEDs: 100 pieces 5050 SMD
IC type: Built-in WS2812
IC quantity: 100 pieces
Color: RGBIC
Working voltage: DC 12V
Current: 1.08A
Power: 13W
Luminous flux: 20lm/LED
Wavelength: 620-625nm(red), 520-525nm(Green), 465-470nm(Blue)
Beam angle: 120°

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