Cás-staidéar August 2026 · 7-Day Sprint

Bespoke Hub Board for
P0.78 COB Medical Device

A medical device developer creating vision testing equipment needed a single standalone P0.78 COB LED module to function as a calibrated stimulus display. But a standard LED module cannot operate independently — it requires a purpose-built Hub Board to bridge the receiving card, power supply, and diode array. With the standard Hub Board designed for 4-8 modules and physically too large, DOIT VISION engineered a bespoke miniaturized Hub Board with ultra-low-profile FPC connectors, custom NovaStar configuration files to force recognition of the unusual standalone hardware, and a precision dual-voltage Common Cathode power circuit. The entire 7-day sprint covered concept through CAD, custom PCB printing, FPC connector assembly, and successful first light-up test.

Pic picteilíní

P0.78

COB · 150x150mm module

amlíne

Laethanta 7

Concept to first light-up

Custom PCB

Hub Board

Miniaturized · Single-module

voltage

Dual

2.8V + 3.8V Common Cathode

Seachadadh ag Foireann Innealtóireachta DOIT VISION · · Athbhreithnithe ag Kris Liang, Comhbhunaitheoir · Lúnasa 2026

CE · EMC · RoHS

15 Innealtóir · Foireann 60 Duine i Shenzhen

55+ Tír · NovaStar · Colorlight

PCB comhrianta + solúbthaMooncell + ResolueTionól Poka-Yoke

Forbhreathnú Tionscadail

Ar Sracfhéachaint

Cliant

Forbróir Feistí Leighis

Vision / ocular testing equipment

Modúil

P0.78 COB 150x150mm

Single standalone module

Inghnóthaithe

Custom Hub Board

Miniaturized single-module bridge

Rialú

NovaStar + Custom .rcfgx

Forced hardware recognition

nascóirí

Ultra-Low-Profile FPC

Medical enclosure constraints

Dearadh Cumhachta

Dual-Voltage CC

2.8V + 3.8V precision split

Dúshlán Eochair

Zero Thermal Hotspots

Must not skew ocular results

amlíne

7-Day Agile Sprint

Concept to successful first light

01 — The Hub Board Problem

Why a Standalone Module Won't Light Up

A standard LED module needs a Hub Board to function. The Hub Board is the bridge between the receiving card, power supply, and the LED diode array — it distributes data signals, manages power routing, and provides the physical connectors for data and power input.

Standard Hub Boards are designed for 4-8 LED modules, with corresponding physical dimensions that make them far too large for a medical device enclosure. The client needed to drive a single module — requiring a purpose-built, miniaturized Hub Board physically matched to the 150x150mm module footprint.

02 — Connector Engineering

Ultra-Low-Profile FPC Design

Standard 120/100-pin connectors were too bulky for the medical device's spatial constraints. For a device that sits millimeters from the patient's face, every fraction of a millimeter in connector height matters.

We sourced ultra-low-profile FPC (Flexible Printed Circuit) connectors — flat ribbon-style interconnects that fold into the enclosure with a profile measured in fractions of a millimeter. These are typically used in smartphone and tablet manufacturing where every micron of internal height is contested.

Beyond physical fit, the FPC connectors had to maintain signal integrity at P0.78 pixel pitch. At sub-1mm pitch, the data rate required to drive the pixel array creates electromagnetic interference (EMI) and electromagnetic compatibility (EMC) challenges that don't exist at coarser pitches. Signal trace length, impedance matching, and ground plane continuity on the custom PCB were all designed to suppress crosstalk and maintain clean data channels.

03 — Power Engineering

Dual-Voltage Common Cathode Circuit

The COB module uses Common Cathode architecture, where red, green, and blue LED channels require different forward voltages. Red needs ~2.8V while green and blue need ~3.8V — driving all three at the same voltage wastes power and generates excess heat.

The custom Hub Board included a precision dual-voltage power circuit that splits the single power supply input into two independently regulated outputs: 2.8V for the red channel and 3.8V for the green and blue channels. This Common Cathode design reduces power consumption by 20-25% compared to Common Anode designs that drive all channels at the same voltage.

Why Thermal Matters in Medical Vision Testing

The client's ocular testing equipment presents calibrated visual stimuli to the patient while measuring pupil response and eye movement. If the LED module generates thermal hotspots — even localized hotspots of a few degrees Celsius — the resulting air convection currents near the patient's face can trigger blink reflexes and skew test results. The Hub Board's power circuit and PCB layout were engineered to distribute heat uniformly across the board surface with no measurable hotspots.

04 — Custom Firmware

NovaStar .rcfgx Configuration

The NovaStar receiving card expects to drive a standard cabinet configuration — typically 4-8 modules in a defined layout. Connecting it to a single miniaturized module with an unconventional connector arrangement would normally result in the receiving card failing to recognize the hardware or driving the pixels in the wrong order.

DOIT VISION wrote a custom .rcfgx configuration file — NovaStar's hardware descriptor format — that explicitly tells the receiving card how many pixels exist, their electrical mapping to channels, and the signal timing for this specific non-standard configuration. The file was loaded via NovaLCT (NovaStar's LED Configuration Tool) and forced the receiving card to recognize the unusual standalone hardware.

De réir na hUimhreacha

Sonraíochtaí Innealtóireachta

P0.78

COB Pixel Pitch

150x150mm single module

Day Sprint

Concept to successful first light

2.8V + 3.8V

Dual-Voltage Output

Common Cathode precision split

20-25%

Coigilteas Cumhachta

vs. Common Anode single-voltage

Sub-mm

FPC Connector Profile

Ultra-low-profile for enclosure

Thermal Hotspots

Uniform distribution via PCB layout

Conas a Sheachaideamar

7-Day Hub Board Sprint

Céim 01

Constraint Lock

Mapped the medical enclosure: single P0.78 COB 150×150mm module, ultra-low-profile FPC, dual-voltage Common Cathode, EMI/EMC budget, and NovaStar receiving-card interface.

Céim 02

Leagan Amach PCB

Miniaturized Hub Board for one module instead of the standard 4–8 module board. Routed 2.8V / 3.8V rails, FPC landing, and thermal copper pours to eliminate hotspots.

Céim 03

Fabricate & Configure

Board fab, connector seating, and custom .rcfgx authoring so NovaLCT recognizes the non-standard single-module geometry on first flash.

Céim 04

First-Light Test

Thermal camera verification (zero hotspots), stimulus uniformity check, and handoff of the Hub Board + config file for the vision-testing device.

Need custom PCB engineering?

Hub Boards, interface boards, custom controllers — we design and fabricate bespoke PCBs from concept to first-light test. Agile sprints from 7 days.

Labhair le hInnealtóir →

Ceisteanna an Cheannaitheora

Ceisteanna Coitianta

Can DOIT VISION design custom interface boards for LED modules?

Yes. Hub Boards, receiving card adapters, power distribution boards, and custom interface PCBs are all within our design capability. We handle PCB layout, fabrication, connector sourcing, and configuration file authoring as a turnkey service. This P0.78 Hub Board went from concept to first-light test in 7 days.

What is a Hub Board and why does a single LED module need one?

A Hub Board bridges the receiving card, power supply, and LED diode array. It distributes data signals, manages power routing, and provides physical connectors. Standard Hub Boards are designed for 4–8 modules — a single standalone module requires a purpose-built miniaturized board.

How do Common Cathode dual-voltage circuits save power?

Red LEDs require ~2.8V forward voltage while green and blue require ~3.8V. Common Anode designs drive all channels at the same higher voltage, wasting power on the red channel. Common Cathode splits the supply into two independently regulated outputs, delivering each channel exactly the voltage it needs — saving 20–25% power and reducing heat generation.

How do you get NovaStar cards to recognize non-standard configurations?

We author custom .rcfgx configuration files that explicitly describe the pixel array geometry, electrical mapping, and signal timing. These files are loaded via NovaLCT and force the receiving card to recognize non-standard hardware arrangements that would otherwise be rejected.

What is the minimum turnaround for custom PCB engineering?

This P0.78 Hub Board was a 7-day sprint from concept to first-light test. Simple interface boards with standard connectors can be delivered in 5–7 days. Complex multi-layer PCBs with custom connectors and power circuitry typically take 2–3 weeks depending on fabrication lead time.

Can you integrate LED modules into medical or scientific equipment?

Yes. We manage the additional requirements: EMI/EMC compliance for signal integrity, thermal management to prevent hotspots that could skew testing, ultra-low-profile connector design for tight enclosures, and custom processor configuration files. We work with your enclosure constraints and certification requirements from the PCB layout stage.

Do you provide EMI/EMC support for medical device LED integration?

Yes. Layout choices — ground planes, differential routing, ferrite placement, and connector shielding — are decided at schematic stage. We coordinate with your device certification lab so the Hub Board does not become the EMI failure point during final EMC testing.

Can the custom Hub Board work with controllers other than NovaStar?

Yes. The electrical interface can be adapted for Colorlight, Linsn, or Brompton Tessera receiving cards. We rewrite the configuration file for that ecosystem and re-validate first-light mapping before shipment.

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Foireann Innealtóireachta DOIT VISION 15 innealtóir inmheánach · saoráid 60 duine i Shenzhen · Athbhreithnithe ag Kris Liang, Comhbhunaitheoir · 19 mbliana innealtóireachta taispeántais LED · 55+ tír a sheirbheáil