LED Moulding

A relatively new technique in LED technology is the casting (moulding) of LED applications. This moulding technique is increasingly being used and suitable for almost any application. The moulding is done with a soft transparent polyurethane or silicone which is 100% safe, does not affect the phosphor of the LED and protects the housing of the LED against voltage and mechanical stress.


Reinforce positive traits

The positive properties of LED are reinforced by moulding. Positive properties of moulded-in LED applications are for example;

  • Protects against extreme influences such as chemicals and weather conditions
  • Shock and vibration resistant, extends component and solder life.
  • Very strong and durable IK value 10 (vandal-resistant)
  • UV resistant so does not discolour / yellow
  • Better mechanically loadable (ideal for LED in paving and floors)
  • Completely waterproof (IP68) while retaining heat dissipation, allowing high capacities
  • Guarantee from 5 to 10 years

Requirements for application

LED casting is always done entirely according to application and order-specific requirements. In order to meet such requirements, Zirqle has a department that is engaged in the casting of LED apllications. This space is specially designed for moulding and professional dispensers provide a constant quality guarantee.


Level of transparency

By implementing several layers of polyurethane or silicone, it is possible to obtain a different degree of transparency, for example from completely clear (hot spots visible), semi-diffuse (partially) to completely diffuse (even light image).


High-quality light image

For certain applications it is essential that the surface is smoothed. This is done by means of flat milling. To be able to continue to guarantee a high-quality light image during face milling, Zirqle has developed a milling machine that can mill without affecting the light image.



During the finishing, the polishing of the top layer of polyurethane or silicone, Zirqle has the opportunity to fully adapt the finish to the requirements set by order. Zirqle uses various methods of finishing from completely matt, glossy (high gloss) to a structured finish. Projects that require a completely seamless finish, such as light lines in a natural stone floor, are poured and finished on location.


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