How LED Spherical Screen & LED Inner Spherical Dome Screen Are Manufactured

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  • How LED Spherical Screen & LED Inner Spherical Dome Screen Are Manufactured

    • How LED Spherical Screen & LED Inner Spherical Dome Screen Are Manufactured

    14 views admin 2026-08-20

    • I. LED Outer Spherical Screen (Viewed from outside the sphere)
     
    • 1. 3D Structural Modeling
     
    • Carry out 3‑D modeling according to the sphere diameter, and divide the spherical surface by longitude and latitude. Trapezoidal / rectangular modules are applied at the equator; triangular and narrow special‑shaped modules are used to fill the north‑south poles (top and bottom vertices of the sphere). Standard square modules cannot wrap the spherical surface directly.
     
    • Small‑diameter spheres: Flexible soft modules (FPC flexible boards) are mostly adopted, which are bent and attached directly to the spherical steel frame.
     
    • Large‑diameter spheres: Multiple small special‑shaped rigid modules are used. Flat small pieces are assembled to approximate the spherical surface (similar to a football assembled by pentagons and hexagons).
    • 2. Internal Framework (Inside the sphere)
     
    • The inner part is a spherical truss steel frame welded by aluminum / steel, like the skeleton of a hollow basketball. All modules are mounted on this spherical steel frame. Layout inside the sphere:
     
    • Power supply: Distributed power supply, arranged dispersedly on the frame to avoid concentrated heat generation.
     
    • Receiving cards: Installed dispersedly, with one receiving card nearby for each module.
     
    • Cable troughs: Power cables and network cables are hidden inside the frame, with no wires exposed externally.
     
    • Heat dissipation: Natural heat dissipation for small spheres; cooling fans are installed inside large spheres.
     
    • Hoisting / floor‑standing base: Top lifting points or bottom load‑bearing base.
     
    • 3. Module Assembly
     
    • Soft modules: Flexible PCB circuit boards, bonded / locked onto the curved frame from the back, and bent to fit the spherical surface.
     
    • Special‑shaped rigid modules: Custom trapezoidal and triangular units. Each module is installed at a different angle. Positioning parts are used to guarantee spherical flatness and control assembly gaps.
    • 4. Control System & Software Debugging
     
    • Ordinary LED playback software cannot be used directly. Special sending cards / video processors for irregular spherical screens are required.
     
    • Geometric correction: Spherical distortion mapping for flat‑source videos to eliminate stretching distortion.
     
    • Point‑by‑point brightness and chromaticity correction: Compensate for viewing‑angle differences at various positions on the sphere.
     
    • Content: Spherically‑adapted materials are required. Ordinary videos will be severely distorted if played directly.
     
    • II. LED Inner Spherical Dome Screen (Audience stands inside the sphere)
    • The LED modules face the sphere center. Audiences stand inside the sphere and look up at the dome images, widely applied in science museums and spherical‑dome cinemas.
     
    • The steel frame forms an outer enclosing shell, and all modules are mounted facing the sphere center.
     
    • Most modules are custom trapezoidal and triangular rigid special‑shaped units, assembled ring‑by‑ring from sphere bottom to top to form a complete inward‑concave spherical dome.
     
    • All power supplies, receiving cards and cables are placed in the interlayer between the outer steel shell and LED modules. No circuits or steel frames are visible to audiences inside the sphere.
     
    • Extra‑large inner dome screens may integrate mechanical structures: lifting screens, access doors, and wire‑stunt hanging points.
     
    • Control: Spherical‑dome geometric correction algorithm delivers 360° panoramic dome visuals, matched with dedicated spherical‑dome movie materials.
    • III. Core Differences Between the Two Types
     
    • IV. Common Technical Challenges
     
    • 1. No off‑the‑shelf standard modules; full customization, with much higher cost than conventional LED screens.
     
    • 2. Difficult control of spherical assembly gaps; triangular modules at sphere vertices represent the highest process difficulty.
     
    • 3. Dense internal cabling; heat dissipation is critical for large‑size spheres.
     
    • 4. Ordinary source videos suffer severe stretching distortion during playback; spherical geometric correction is mandatory.
       
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