In the world of LED lighting, customization often means taking a standard product and transforming it into something entirely different. Sometimes, the most interesting projects come from reimagining what a product can do.
This is exactly what happened with a recent project involving a strobe warning light — the type commonly used on passenger vehicles, trucks, school buses, and engineering vehicles to alert other drivers.
This project was Benjamin‘s second order with us — a testament to the trust we built through our first collaboration. The complexity of this multi‑product integration is best appreciated through the full story.
Explore the complete case: Featured Case Study: Multi‑Product Integration Challenge →
This strobe warning light is one of three products included in that larger project. Each product required its own custom design, but together they formed a cohesive solution for Benjamin’s application.
The client had a vision: take a standard single‑color strobe light and turn it into an SPI‑controlled RGB pixel light using the UCS1903 protocol.
Here is how we brought that vision to life.
The Challenge: From Single-Color Strobe to SPI Pixel Light
The standard strobe warning light is simple:
Feature | Standard Configuration |
|---|---|
Function | Single-color flashing (red, amber, or blue) |
Control | On/off flashing, no color control |
Typical use | Emergency and warning vehicles |
The client's requirement was completely different:
Requirement | Client's Request |
|---|---|
Control | SPI protocol (UCS1903) |
LED type | SMD5050 RGB (full color) |
Effect | Programmable pixel effects, not just flashing |
Application | LED lighting projects (beyond vehicle use) |
This meant we needed to completely redesign the internal lighting system while keeping the same housing and form factor.
Our Solution: A Custom PCB Design
The existing strobe light structure was never designed for SPI control or RGB LEDs. We had to start from scratch.
The Internal Structure Challenge
Inside the warning light housing, space was limited. The client's requirements included:
Component | Requirement |
|---|---|
Bottom PCB | A round PCB at the base |
LED strips | 8 rigid LED strips (10cm each) arranged around the perimeter |
Connection | All 8 strips connected in series |
Control | SPI (UCS1903) |
The Design
We designed a custom PCB system consisting of:
Component | Specification |
|---|---|
Round base PCB | Holds the ICs and provides structural support |
8 rigid LED strips | 10cm length, 6 LEDs per strip (SMD5050 RGB) |
Total ICs | 8 UCS1903 ICs (1 per strip) |
Total LEDs | 48 SMD5050 RGB LEDs (8 strips × 6 LEDs) |
Voltage | DC24V |
Waterproof rating | IP65–IP66 |
Connector | 3-pin black parallel wire (30cm), 3-pin waterproof M8 male connector |
Space Constraints: A Real-World Adjustment
One significant challenge we encountered was the internal space limitation. The actual internal length of the housing was only 7.5cm — not enough for 10cm strips.
We adjusted the strip length to 7cm to ensure a proper fit without compromising the structural integrity of the housing.
Original Specification | Actual Adjustment |
|---|---|
10cm rigid strips | 7cm rigid strips (to fit 7.5cm internal length) |
This adjustment required careful re-engineering of the PCB layout to maintain the correct spacing and interconnection between strips.
Wiring and Connection Design
Serial Connection of Strips
The 8 rigid strips are connected in series, not in parallel. This means:
Data flows from one strip to the next (daisy-chain)
Each strip has its own UCS1903 IC
All 48 LEDs are individually addressable
Connection | Details |
|---|---|
Strip connection | Series (daisy-chain) |
IC per strip | 1 UCS1903 (8 total) |
LEDs per strip | 6 SMD5050 RGB (48 total) |
Control protocol | SPI (UCS1903) |
Waterproof Connector
The client specified a 3-pin M8 waterproof male connector, compatible with:
3-core black parallel wire (with white edge for polarity identification)
UCS1903 LED strip systems (plug-and-play compatibility)
Screw-locking mechanism for secure connection
Connector Feature | Specification |
|---|---|
Type | 3-pin M8 waterproof male |
Wire | 3-core black parallel (with white edge) |
Locking | Screw-type (secure) |
Compatibility | Direct plug-in for UCS1903 LED strips |
Length | 30cm pigtail |
Final Product Specifications
Component | Specification |
|---|---|
Base PCB | Round PCB (custom design) |
LED strips | 8 × 7cm rigid strips (6 LEDs/strip) |
Total LEDs | 48 SMD5050 RGB |
IC type | UCS1903 (8 ICs) |
Voltage | DC24V |
Waterproof rating | IP65–IP66 |
Connector | 3-pin waterproof M8 male (screw-lock) |
Wire | 30cm 3-core black parallel wire (with white edge) |
Control protocol | SPI (UCS1903) |
Applications
This custom solution is versatile and can be used in:
Application | Why It Works |
|---|---|
Vehicle warning lights | Replaces single-color strobe with RGB pixel effects |
Emergency vehicle lighting | Programmable patterns for different scenarios |
Stage and entertainment | Compact, bright pixel light for events |
Architectural accents | Small footprint, powerful output |
Custom LED projects | Fully programmable, SPI-controlled |
Advertising displays | Eye-catching pixel effects |
Key Benefits of This Custom Design
Benefit | Explanation |
|---|---|
SPI control | Full programmability — chasing, gradients, animations |
RGB color | Any color, not just single-color strobe |
UCS1903 chip | Reliable SPI protocol, widely compatible |
IP65–IP66 waterproof | Suitable for outdoor and vehicle use |
Compact design | Fits into existing warning light housings |
Plug-and-play | M8 connector compatible with standard UCS1903 systems |
Customizable | Can be adapted for other shapes and sizes |
Lessons Learned
Lesson | Why It Matters |
|---|---|
Measure twice, engineer once | The internal length of 7.5cm required us to shorten the strips from 10cm to 7cm |
Series connection works | 8 strips in series with UCS1903 ICs performed reliably |
Waterproofing is critical | IP65–IP66 rating ensures durability in outdoor and vehicle environments |
Compatibility matters | M8 connectors with 3-core wire ensured easy integration |
Custom PCB design is key | Standard off-the-shelf components could not achieve this result |
Final Thoughts
What started as a simple request — "Can you make a strobe light with SPI control?" — turned into a full custom PCB design project involving 8 rigid strips, 48 RGB LEDs, and 8 UCS1903 ICs in a compact housing.
The result is a product that transforms a standard single-color warning light into a fully programmable RGB pixel light — suitable for vehicles, stage productions, architectural accents, and custom LED projects.
If you have a standard product that you want to reimagine with SPI control, custom PCB design, or RGB LEDs, we are ready for the challenge.
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