Before designing a UV LED module, the most useful inputs are the required wavelength, optical performance target, PCB dimensions, and available power supply or driver parameters. Working distance, illuminated area, and cooling arrangements help turn those inputs into a configuration that can be evaluated before a board is made.
Customers do not need to select every component or calculate every operating parameter themselves. If the requirements are clear, NKT can design around them. If component choices are still open, NKT can recommend LED models, quantities, operating currents, and arrangements.
The important distinction is between having enough information to start a discussion and having an agreed basis for detailed PCB design.
What LED Quantity and a Drawing Leave Unanswered
In one NKT UV module project, the customer initially provided LED quantities and a dimension drawing. Optical output requirements were unavailable despite follow-up questions. Preliminary output targets were supplied later as the project progressed.
That sequence made the early design work less efficient. When performance requirements are introduced later, decisions already made about components, current, or placement may need to be reconsidered.
A board can accommodate the requested LEDs and still need changes to meet the application target. Increasing the LED quantity may affect routing. Selecting a different LED may change the footprint or electrical configuration. A revised current requirement may require another review of the supply and cooling conditions.
LED quantity and board dimensions should therefore be checked against the performance requirement before detailed layout begins.
The related 405nm + 450nm LED module project shows how component selection and PCB development interact in an OEM curing application.
Start With the Optical Target and the Conditions Behind It
A request for a particular “power” needs a unit and a clear meaning. Electrical input power and total radiant power are both expressed in watts, but they describe different quantities. Irradiance, expressed in mW/cm² or W/cm², describes the optical power received per unit area at a specified surface.
For curing equipment, total radiant power alone does not establish what reaches the material. The working distance, LED arrangement, illuminated area, and optical components affect the irradiance at that surface.
If an irradiance target is available, provide:
- The required value and wavelength.
- The distance from the LED module to the working surface.
- The dimensions of the area to be illuminated.
- Whether the target applies to the center, an average, or a minimum across the area.
If the process already has a dose or exposure-time requirement, include it as well. There is no need to invent a value simply to complete an inquiry; identify what is known and what still needs to be established.
NKT can use the application conditions supplied by the customer to estimate performance and assess possible configurations. The customer determines the intended working distance and coverage requirements and confirms them through equipment testing.
How NKT Uses Estimates to Develop the Proposal
Early estimates help determine which configuration is worth building.
NKT estimates total radiant power using the selected LEDs’ datasheet information, quantity, and proposed operating current. With the relevant working distance, target area, and arrangement information, NKT also estimates irradiance to assess the proposed configuration against the customer’s requirements.
These estimates guide practical decisions: which LED to use, how many are needed, what current to propose, and how to arrange them within the available space.
The proposal can also include estimated operating voltage and electrical power. Reviewing these values together helps identify conflicts before they become PCB revisions—for example, when a proposed LED quantity does not suit the available driver or when the requested output requires a different configuration.
The purpose of the estimate is to support a design decision. Its assumptions should be clear enough for the customer to review, including the operating current and application geometry used. Sample measurements then check the proposed performance and provide a basis for adjustment.
Provide the Electrical and Mechanical Constraints Together
The following information helps NKT connect the performance target with a practical module design.
| Input | What to provide | Why it matters |
|---|---|---|
| Wavelength and LED selection | Required wavelength; specified manufacturer and complete part number, if any | Establishes the component requirements and identifies where recommendations are welcome |
| Driver or power supply | Model or datasheet, output voltage range, available current, and constant-current or constant-voltage operation | Supports the electrical configuration and operating-point review |
| Channel operation | Separate wavelength channels, independent or simultaneous operation, and relevant switching or dimming requirements | Defines how each part of the module will operate |
| PCB and installation drawing | Outline, holes, cutouts, keep-out areas, height limits, and connector positions | Defines the space available for LEDs, components, and routing |
| Cooling and operating mode | Planned heatsink interface, cooling arrangement, and continuous or intermittent operation | Provides context for current selection and performance estimates |
Identify which requirements are fixed and which can be adjusted. A customer-specified LED quantity is a different starting point from a quantity that NKT is free to recommend.
If the driver is not yet selected, provide the equipment’s available electrical limits. NKT can propose the module’s operating requirements for the customer to use when reviewing supply options.
For drawings, use a clearly identified revision and highlight subsequent changes. A connector or mounting change can affect an otherwise completed layout.
Agree on the Design Basis Before Layout Begins
The initial review should lead to a configuration that both sides understand: the proposed LED model and quantity, operating current, electrical requirements, arrangement, and expected optical performance under the stated conditions.
If a key target is still uncertain, agree on a provisional value or range and identify what remains open. When that uncertainty could substantially change the component selection or layout, resolving it first can prevent work from having to be repeated.
This is where NKT’s recommendations are useful. Customers who have not finalized the LED selection can review a proposed combination of components and operating conditions instead of choosing each parameter separately.
The same agreed conditions should guide prototype verification. For an irradiance comparison, record the measurement distance and position, operating current, and relevant thermal conditions. An area-wide requirement needs measurements that represent that area, rather than only a center reading.
NKT’s module evaluation and the customer’s equipment testing then address their respective parts of the project. The customer confirms coverage, operating temperature, and final curing performance in the application.
What to Send With Your Inquiry
Send your available optical requirements, PCB drawing, and driver or power supply details. Include any specified LEDs or connectors, the intended working distance and illuminated area, and your sample and expected production quantities.
Mark the items that are open for recommendation. This allows NKT to focus the initial review on the decisions that need engineering input and establish the design basis before detailed PCB work begins.
For more about our custom UV LED module development support, visit our UV application page.
Send your drawings and requirements to discuss a suitable module configuration.