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Creative & Custom LED Displays Custom Shaped LED Display
for a Tokyo Nightclub
Buyers searching for an LED cylinder, LED column, LED ring, or flexible LED display usually want a known form factor. This Tokyo project went further: a variable-diameter 3D “horn” surface that expands continuously from a narrow base to a flared bell. Partnering with SPACEWA for a premier Tokyo nightclub, DOIT VISION built it from two module types — custom-contour rigid PCBs (six distinct shapes, like rind panels tiling a sphere) plus flexible LED modules on the tightest curves — then shipped a Poka-Yoke kit for overseas assembly and mapped content through Mooncell into Resolume Arena.
At a Glance
Not Another Cylinder or Ring
Standard nightlife installs lean on familiar forms: an LED column beside the DJ booth, an LED ring over the dance floor, an LED cylinder wrapping a structural pillar. SPACEWA’s end client — a premier Tokyo nightclub — wanted a form that reads as a giant musical horn: diameter expanding continuously from a narrow base to a flared upper bell.
That geometry is harder than a constant-radius cylinder or ring. Circumference grows with height, so surface area roughly doubles as you move outward. A single rectangular or equal-arc flexible panel cannot tile it cleanly. The venue handed over dimensioned line drawings — two companion forms at 3.7m and 3.0m outer diameter — and asked for a build that local crews could assemble without LED factory experience.
Original client concept drawing — dual flared forms with human scale
Contour PCBs + Flexible Modules
Think of tiling a sphere with watermelon-rind panels: each band needs its own contour. Six distinct rigid PCB shapes covered the stepped diameters; flexible LED modules handled the tightest transitional curves where rigid boards would gap or kink.
Off-the-shelf flexible LED can wrap a gentle column. It cannot alone solve a continuously expanding horn without seams, dead zones, or forced stretch beyond rated bend radius. Our decision: mix two module families at the same P3mm pitch and LED binning.
Custom-contour rigid modules for each diameter band — six PCB geometries designed, fabricated, and tested in a 20-day sprint. Flexible modules only where curvature changes fastest. Same pitch across both types so the eye reads one continuous surface — not a patchwork of product lines.
If you are comparing suppliers after searching “LED cylinder” or “flexible LED display,” this is the differentiator: we will tell you when flexible alone is enough, and when you need contoured boards like this project.
Custom contoured module / PCB — factory bench
Production — frame and module integration
Foolproof Overseas Assembly
The Tokyo install team had zero LED manufacturing experience. Shipping six board contours across the ocean meant one wrong placement would cascade into assembly failure. DOIT VISION designed a complete Poka-Yoke (mistake-proofing) system:
- Color-Coded LabelingEach PCB type received a unique color and shape symbol matched to a printed assembly map.
- Modular Aluminum FramePre-installed wiring and blind-mate connectors — no soldering, no crimping; hex key only.
- Step-by-Step Video ManualsQR codes on each crate linked to videos for that crate’s exact components.
Factory frame assembly before overseas shipment
Mooncell-to-Resolume Mapping
The Empty Pixel Bounding Box
Resolume Arena expects rectangular canvas inputs. A variable-diameter 3D surface does not. Mooncell mapped every physical LED into a flattened 2D bounding box with empty pixels filling the gaps.
For the 3.7m form, that canvas is 1233×1233 pixels. The VJ drops a standard loop onto it — empty pixels are skipped by the processor — and visible content wraps the 3D form.
Early mapping passes under-counted LEDs on the flared bands, so Resolume showed clipped or stretched content. We re-walked the contour PCB address map band by band, corrected the empty-pixel mask, then verified live with the VJ over video link during Tokyo install. The “hospital chart” detail: wrong counts look like a creative bug — they are almost always a geometry bookkeeping bug.
The bounding box means the resident VJ uses Resolume like any flat LED wall — no special plugins, no custom software. Complex 3D-to-2D mapping stays at the processor.
Control software UI — mapping and configuration
Lit On the Tokyo Floor
After factory build, crate-coded shipping, and on-site assembly with SPACEWA’s local crew, both custom shaped forms went live in the nightclub — continuous red/mesh content wrapping the flared surfaces, reading as architecture as much as screens.
Quantified outcomes: six PCB contours delivered in a 20-day sprint; zero assembly errors under the Poka-Yoke kit; 1233×1233 Resolume canvas for the larger form; remote video-link debug closed the pixel-count gap before opening night content locked.
For buyers still comparing a flexible LED column or ring quote: this project is the proof that when geometry leaves constant-radius forms, contour modules plus flexible sections — not marketing adjectives — decide whether the surface looks continuous.
Opening look — custom shaped forms lit in venue
Project Specs
From Contour CAD to Tokyo Floor
Geometry Capture
Client line drawings → CAD. Six contour PCB bands mapped to each diameter level of the expanding form.
PCB + Flexible Sprint
6 custom contours designed, fabricated, and tested in 20 days. Flexible modules reserved for the tightest curves.
Poka-Yoke Ship
Color-coded crates, QR video manuals, pre-wired frames. SPACEWA’s Tokyo crew assembled with zero prior LED factory experience.
Remote VJ Lock
Mooncell-to-Resolume empty-pixel map configured. Video-link debug fixed pixel-count errors during install.
Export packing and loading — overseas shipment to Tokyo
Need a custom shaped LED — not just a cylinder?
We design contour PCBs, flexible modules, and foolproof assembly kits for non-standard 3D forms. Feasibility assessment within 48 hours.
Frequently Asked Questions
Can DOIT VISION build custom shaped LED displays — not only cylinders, columns, or rings?
How is this different from buying a flexible LED display alone?
How do you map video onto a non-flat custom shaped LED?
What if our installation crew has no LED assembly experience?
How fast can custom contour PCB designs be turned around?
What control systems do you support for creative LED installs?
What is the minimum project size for a custom shaped LED like this?
Products & Resources
Flexible LED Displays
Bendable flexible LED modules for columns, curves, and creative installs — and the flexible half of contour+flex builds like this case.
Explore →Creative LED Displays
Custom shaped LED: cylinders, columns, rings, spheres, and non-standard geometries with full contour PCB engineering.
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Pixel pitch, resolution & viewing distance calculator for any display configuration.
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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.
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