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Displays de LED criativos e personalizados Retrofitting P1.8 COB LED Stairs
at the Johnny Cash Museum
Integrar telas digitais em novas construções é simples. Mas incorporar telas de LED de alta definição em um patrimônio histórico totalmente acabado e de grande circulação, sem alterar a estrutura existente, exige engenharia. O Museu Johnny Cash solicitou à DOIT VISION a transformação de uma escadaria central de madeira com 12 degraus em uma tela digital dinâmica. Utilizando engenharia de valor com módulos COB padrão de 320×160mm, perfis de alumínio ultrafinos e encapsulamento em epóxi resistente a impactos, todo o sistema foi projetado, fabricado e entregue em apenas 15 dias.
Num relance
The Strict Dimensional Constraints
The client provided the exact, unchangeable dimensions of the existing staircase:
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Total de etapas12 elevadores
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Altura do riser5 7/8" (approx. 150mm)
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Riser Width11 steps at 77.5" (1968.5mm) + 1 bottom step at 61" (1549.4mm)
The dilemma was clear. Standard LED cabinets are bulky — usually 500×500mm or 1000×250mm — which would completely ruin the depth of the stairs or protrude past the rounded lips of the wooden treads. Custom-sized PCB boards for a relatively small 12-step project would skyrocket R&D costs and blow the museum's budget.
Standard Modules, Custom Results
Instead of reinventing the wheel with expensive custom circuit boards, our engineering team looked at the client's dimensions and immediately identified a mathematical synergy with our standard mass-produced modules.
Selecionamos nosso padrão Módulos de LED COB P1.8 de 320×160mm. The 160mm module height was a near-perfect fit for the 150mm exposed riser height, maximizing visual area without a single custom PCB. By placing 6 modules horizontally (320mm × 6), we achieved an exact width of 1920mm — perfectly centered within the 1968.5mm stair width with a clean, symmetrical margin on both sides.
This value engineering approach — using standard modules creatively instead of designing bespoke PCBs — saved the museum tens of thousands in custom fabrication costs while keeping the 15-day delivery timeline achievable.
Ultra-Slim Profile Design & Wiring
Nós projetamos sob medida. armários com perfil de alumínio ultrafino measuring exactly 1920×160mm — rigid backbones that added minimal depth to the existing stairs.
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Direct Screw-MountingBecause the stairs were wood, the local crew simply drove screws from behind the stairs directly into the aluminum frames — no messy brackets, no structural alteration.
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100% Front-ServiceableCOB modules attach via heavy-duty magnets. If a module ever needs replacement, a technician pulls it off from the front with a suction tool — no disassembly required.
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Hidden InfrastructureAll power supplies and receiving cards were routed behind the hollow wooden stair structure, keeping the face of the stairs completely clean.
From Shenzhen to Tennessee in 15 Days
By heavily utilizing standard 320×160mm COB modules rather than drafting custom PCBs, we slashed the production timeline drastically. The complete 12-step system was manufactured, tested, and dispatched in just 15 dias .
Upon arrival in Tennessee, the client's local crew handled the physical mounting smoothly thanks to the plug-and-play design. DOIT VISION's support team then stepped in via remote video link to map the 12 separate risers in software, digitally stacking them so that when the museum plays a video, content cascades seamlessly up and down the stairs as a single unified canvas.
True engineering mastery isn't always about building the most complex custom circuit board. Often, it's about having the intelligence to use standard, highly reliable components in creative ways to solve strict physical constraints, respect budgets, and crush delivery deadlines.
Why COB is Mandatory for Stair Displays
Specifying the right LED packaging technology is the difference between an installation lasting 5 years or 5 days. For any display installed at foot level, SMD is a liability.
A vulnerabilidade do SMD
Standard SMD (Surface-Mounted Device) screens consist of millions of tiny LED bulbs soldered onto a board. A single accidental kick from a shoe shears off multiple diodes, resulting in permanent dead pixels — unacceptable in a premium museum environment.
COB (Chip-on-Board) directly bonds the LED chips to the PCB, which is then completely coated and sealed in hardened epoxy resin. This creates a flat, smooth surface with Classificação de dureza 5H — highly resistant to scratches, kicks, and direct impacts. Because the surface is sealed, it's inherently water-resistant, meaning museum staff can safely wipe down and clean the stairs without damaging internal electronics.
Especificações do projeto
15-Day Retrofit Process
Dimensional Capture
Fixed dimensions verified: 150mm risers, 1968.5mm / 1549.4mm widths. Value engineering identified 320×160mm module synergy.
Aluminum Profile Fab
Custom 1920×160mm ultra-slim aluminum profiles fabricated with rear screw-mounting points and magnetic module interface.
Production & Dispatch
12 complete COB stair assemblies manufactured, tested, and dispatched in 15 days. All power and data pre-routed.
Remote Pixel Mapping
Local crew handled physical mounting. DOIT VISION engineers mapped 12 risers remotely — content cascades as one unified canvas.
Planning a retrofit installation?
Don't demolish your existing architecture just to fit standard LED cabinets. Our engineering team uses ultra-slim profiles and standard module synergy to save you thousands in custom fabrication costs.
Perguntas frequentes
Can LED displays be installed on existing staircases without demolition?
Why is COB mandatory for stair and floor LED applications?
What's the advantage of using standard modules over custom PCBs?
How do you map content across multiple stair risers as one canvas?
How fast can DOIT VISION deliver a stair LED retrofit?
Is front maintenance possible on stair LED installations?
Produtos e Recursos
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