Case
Project Case | Outdoor Double-Sided LED Digital Sign – Delta, MO, USA
Location: Delta, Missouri, USA
Display Size: 4’ × 8’ (Double-Sided)
Pixel Pitch: P6
Brightness: 10,000nits
Cabinet Type: ONLYLED U-PRO-L Outdoor Aluminum LED Cabinets (2’ × 4’)
Project Case: 1×2ft Aluminum LED Modules with Common Cathode LEDs for 10000nits Outdoor LED Signs
ONLY LED’s 1×2ft aluminum LED display modules represent a new generation of outdoor LED signage technology, engineered specifically for high-brightness, long-lifespan, and extreme outdoor environments. Designed, manufactured, and tested entirely by ONLY LED, these modules are widely used in 10000nits outdoor LED signs, digital billboards, and DOOH applications across the U.S. market.
Advanced Aluminum LED Module Structure
Each 1’×2’ LED module features a full die-cast aluminum housing with an ultra-slim profile of less than 10mm thickness, delivering both structural strength and modern aesthetics. Unlike conventional plastic LED modules, the LED PCBA in ONLY LED’s design is directly integrated and tightly bonded to the aluminum housing. This integrated structure allows the aluminum body to serve as both a mechanical frame and a high-efficiency heat dissipation system.
This design significantly improves reliability, flatness, and thermal performance—three critical factors for outdoor LED signs operating 24/7 under strong sunlight.
Superior Heat Dissipation for High-Brightness Outdoor Use
One of the biggest challenges for 10000nits outdoor LED displays is heat management. Aluminum has a thermal conductivity more than 200 times higher than plastic, allowing heat generated by LEDs and driver ICs to be rapidly transferred and dispersed.
As a result:
LED junction temperatures remain lower
Brightness remains stable even under direct sunlight
Component aging is significantly slowed
Overall LED display lifespan is extended
This makes ONLY LED aluminum modules especially suitable for hot-climate regions, such as the southern United States, where traditional plastic modules often fail prematurely.
Fire Resistance and Safety Advantage
Safety is another critical advantage of aluminum LED modules. Unlike plastic housings, aluminum modules are non-combustible. Even in the event of a nearby fire or extreme electrical failure, aluminum modules do not ignite or propagate flames, dramatically reducing safety risks.
For outdoor LED signs installed at schools, churches, shopping centers, gas stations, and roadside locations, this fire-resistant property provides added peace of mind and compliance with stricter safety expectations.
High Flatness for Premium Visual Performance
ONLY LED’s aluminum modules are manufactured with extremely high flatness tolerance, ensuring seamless alignment between modules. This eliminates common issues found in plastic modules such as warping, deformation, or visible panel depressions.
The result is:
A flatter LED display surface
Smoother images and videos
Better uniformity and viewing comfort
A more professional, high-end appearance
This is especially important for outdoor full-color LED signs viewed from long distances.
IP67 Protection for Harsh Outdoor Environments
ONLY LED aluminum LED modules achieve an IP67 waterproof rating, exceeding most outdoor plastic modules that typically range from IP65 to IP66. The higher protection level effectively prevents:
Rainwater intrusion
Humidity damage
Dust and sand accumulation
This makes the modules highly reliable for long-term outdoor installations, including coastal areas and regions with heavy rainfall or snow.
Common Cathode LEDs: Energy Saving Meets Performance
ONLY LED aluminum modules are paired with common cathode LED technology, delivering up to 20% energy savings compared to traditional common anode systems. By precisely controlling voltage and current for each color channel (R, G, B), common cathode LEDs reduce unnecessary power consumption and heat generation.
Key benefits include:
Lower operating temperature
Reduced power bills
Enhanced LED lifespan
Improved long-term brightness stability
When combined with aluminum housing, common cathode LEDs create an ideal platform for 10000nits high-brightness outdoor LED signs.
The Future of Outdoor LED Displays
As manufacturing technology advances and production costs continue to decrease, aluminum LED modules are rapidly replacing plastic modules as the industry standard. Their advantages in heat dissipation, safety, flatness, waterproofing, and long-term cost efficiency make them the clear future of outdoor LED display development.
ONLY LED remains committed to this direction by continuously refining aluminum module design and integrating advanced technologies tailored to the American outdoor LED signage market.
Conclusion
ONLY LED’s 1×2ft aluminum LED modules, combined with common cathode LED technology and 10000nits ultra-high brightness, deliver a powerful, durable, and energy-efficient solution for modern outdoor LED signs. From digital billboards to commercial signage, these modules are built to perform where visibility, safety, and reliability matter most.
ONLY LED – Smarter. Brighter. Greener.
