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Collaboration with CCL Design Results in Brighter Solution

CCL Design is a global supplier to many of the world’s leading and most innovative brands. From concept to commercialisation, we collaborate to bring our customers’ products to life. Our expertise spans design, prototyping, and large-scale manufacturing, working cross-functionally to find solutions for even the most complex manufacturing challenges. Our customers trust us to navigate rapidly evolving markets and technologies, turning ambitious ideas into tangible realities, from initial concept to mass production.

When one such brand, a global communications leader, was experiencing issues with a backlit display window module, their existing module supplier proposed a complex solution using multiple LEDs on a Printed Circuit Board Assembly (PCBA). The resulting module’s complexity meant:

• it suffered from uneven lighting and
• the necessary adjustments to the assembly housing caused significant mechanical weakness.

That’s when our customer approached CCL Design to help address these issues and work towards a solution.

Streamlined Design, Unmatched Capabilities: A One-Stop Solution

CCL Design engaged a multi-disciplinary team across the globe who collaborated to identify key opportunities to simplify the module with an innovative design addressing both lighting and structural concerns.

Our significant in-house capabilities meant that each aspect of concern could be addressed by our engineering teams; with their first challenge to minimise LEDs using light guiding technology. Our solution – a single-LED light bar – achieved this goal. Managing the cosmetic gradient at the light bar's ends was crucial for aesthetics. We addressed this through our diffusing film utilising our material and printing expertise. Finally, we focused on the manufacturing, assembly and test processes, delivering a fully-functional module ready for simple assembly into the product housing.

We designed a more streamlined, automated manufacturing process, delivered a more efficient and robust solution and achieved significant cost savings for our valued customer of more than 25 years.

Want to learn more about this case study or partner with CCL Design? Contact us.