All-in-One COB LED TV 
Flexible LED Displays 
Transparent LED Displays 
Led Poster 
Circular LED Displays 
Creative & Custom LED Displays Scaling a 4-Sided LED Pillar for AT&T's National Rollout
The marketing agency representing AT&T wanted to replace outdated flat LCDs at Costco retail booths with an eye-catching 360-degree LED solution — across 600+ stores nationwide. DOIT VISION designed, engineered, and mass-produced 630 units of a custom P2.5 LED pillar in 30 days. Through value engineering, CNC-machined standard 320×160mm modules created near-seamless 90-degree corners instead of expensive custom beveled PCBs, and the 320×960mm per-face design created perfect mathematical harmony — zero waste, zero custom cuts.
At a Glance
Replacing LCDs at National Scale
AT&T's marketing agency wanted to replace outdated flat LCD screens at Costco retail booths with something that would grab shoppers' attention from every aisle. The solution: a towering 4-sided LED pillar displaying 360-degree video content.
But deploying across 600+ Costco locations nationwide meant every design decision had to consider mass-producibility, plug-and-play simplicity, and zero on-site technical support. The local Costco staff — not AV technicians — would be setting these up.
One SKU for all 630 units. No per-store customization. No technician visits after delivery. Content must wrap 360° without a PC at each location. Every pillar must ship pre-assembled, pre-configured, and boot into content on first power-up.
CNC Corners vs. Custom Beveled PCBs
The biggest cost question: how to create near-seamless 90-degree corners across 630 units without blowing the budget on custom beveled-edge PCBs.
Custom beveled PCBs with polished 45-degree edges would have been the premium approach — but at 630 units with 4 corners each, that means 2,520 custom corner modules plus separate PCB NPI, yield loss, and a second spare-parts inventory. The agency's budget could not absorb that at national scale.
DOIT VISION's value engineering solution: use standard 320×160mm modules and CNC-machine the aluminum frame edges to 45 degrees. The modules butt against each other at the CNC-cut angles, creating a near-seamless corner while using entirely off-the-shelf PCBs — the same inventory that serves all 630 pillars.
The per-face design was 320×960mm — exactly 1 module wide by 6 modules high. Four faces = 24 standard modules per pillar. No custom cuts, no PCB waste. This zero-waste geometry was not an accident — it was engineered from the first CAD sketch.
We quoted the beveled-PCB path first. Visual quality at the corner is marginally cleaner — but lead time, NPI cost, and per-unit module price made the CNC frame path the only viable option at 630 units. The first workshop sample validated corner alignment and magnetic front-service access before we opened the production line.
NovaStar TB40 + BrightSign 360°
The NovaStar TB40 controller mapped four independent faces into one continuous 512×384 logical canvas. Each face became a 128×384 pixel zone, with content wrapping across all four sides.
BrightSign asynchronous media players handled content playback at each location — no PC required, no ongoing IT support. Content updates are pushed remotely via cloud, and the entire system powers on automatically when the store opens.
Each pillar shipped as a single pre-assembled unit with internal cable routing and pre-configured BrightSign player. Local Costco staff simply wheel it into position, plug in power, and the pillar boots into 360-degree content automatically — zero configuration, zero technician visits.
The internal aluminum framework was designed with vertical ventilation channels that create a natural chimney effect — cool air enters at the base, rises through the electronics cavity, and exits at the top. No active fans, no moving parts. Thermal camera testing under 24-hour continuous operation validated the passive design before mass production opened.
72-Hour Aging Before Any Unit Ships
Unit #1 and unit #630 run the same QC protocol. At 630 pillars, consistency is not a nice-to-have — it is the product.
Every pillar undergoes a standardized checklist before crating: LED calibration uniformity across all 4 faces, TB40 zone mapping verification, BrightSign playback test, and a 72-hour burn-in with 360-degree content running continuously.
LED modules are batch-calibrated before assembly so color uniformity holds across the entire production run — not just within one pillar, but pillar-to-pillar when a store receives a replacement unit months later.
- 4-face uniformity scanEach face measured against the same reference white point and grey scale before the pillar is approved.
- TB40 + BrightSign lock512×384 canvas mapping and BrightSign playlist verified — no on-site reconfiguration required.
- 72-hour aging linePillars run wrapped content under factory power before any unit leaves Shenzhen.
630 Units Staged, Then Nationwide
Production ran in parallel batches across multiple Shenzhen lines — module inventory pre-staged, CNC frames machined in lots, control systems pre-flashed before final assembly. The result: 630 complete pillars cleared QC and reached the client's US warehouse on schedule.
From there, pillars rolled to Costco locations in regional waves. Each unit arrived as a single crate — pre-assembled, pre-configured, ready for store staff to position and power on.
630 pillars deployed across 600+ Costco stores. One SKU, one spare-parts inventory, one BrightSign content template — national retail rollout without a dedicated AV crew at every location.
Project Specs
How 630 Units Were Delivered
CAD & First Sample
320×960mm zero-waste layout locked. CNC 45° frame geometry validated on a single workshop sample. Beveled-PCB path rejected on cost and lead time at 630 units.
Parallel Mass Production
Standard P2.5 modules batch-calibrated. CNC frames machined in lots. TB40 + BrightSign pre-flashed. Multiple Shenzhen lines running in parallel toward the 30-day target.
Aging & QC Lock
72-hour burn-in per unit. 4-face uniformity scan. 512×384 canvas and BrightSign playlist verified. Same protocol on unit #1 and unit #630.
Warehouse → Nationwide
630 pillars crated pre-assembled. Staged at client US warehouse, then rolled to 600+ Costco locations. Store staff: position, plug in, content auto-starts.
Need mass-produced LED pillars?
From single prototypes to 1,000-unit production runs — we engineer for mass-producibility from the first sketch. Volume quote within 48 hours. MOQ guidance included.
Frequently Asked Questions
Can DOIT VISION handle large-volume LED display production?
How do you keep costs down on high-volume custom LED projects?
What control system works for 360-degree retail LED pillars?
How do you handle thermal management in enclosed LED pillars?
Can retail store staff install these without AV experience?
What's the minimum order quantity for custom LED displays?
How do you ensure consistent quality across hundreds of units?
Products & Resources
Poster LED Displays
Indoor, COB, foldable & trifold poster displays. Pixel pitches from P1.5 to P3.0.
Explore →Fine Pitch LED
P1.2 to P2.5 indoor displays for retail, corporate, and control-room applications.
Explore →LED Display Calculator
Pixel pitch, resolution & viewing distance for any configuration.
Explore →Engineering Case Studies
Browse full library — custom LED engineering across 55+ countries.
Explore →Your Custom Shape, Engineered
Send drawings or a rough diameter/height sketch — we will assess whether a flexible solution alone works. Reply within 48 hours.
WhatsApp an Engineer Get a Quote View All Case Studies