Laser Wire® System
Design Reference

1. System Overview

Laser Wire® is a side-emitting plastic optical fiber (POF) lighting system. Unlike EL wire, which is electroluminescent, or LED strip, which uses individual emitter chips, Laser Wire® uses a laser or high-brightness LED source at one end of a fiber strand to transmit light along the fiber length. The fiber jacket is engineered to scatter a controlled percentage of that light outward along the full run, creating a continuous, uniform glow from any angle.

The result is physically different from any other linear lighting technology:

• No visible point sources: The light along the run has no discernible nodes, chips, or dots at any viewing distance. This is structurally impossible to achieve with emitter-based LED strip and is the primary specification driver for Laser Wire® in architectural and display applications.
• Color uniformity over long runs: Because the color is defined at the source module — not at individual emitters — color consistency along the run is absolute. There is no color shift from end to end.
• Low operating temperature: The fiber itself does not generate heat. The source module produces minimal heat. Laser Wire® can be embedded in materials (foam, fabric, architectural channels) where LED heat output would be problematic.
• Thin fiber diameter: Available from 0.75mm to 3mm diameter, Laser Wire® fiber routes through smaller channels and tighter bends than any LED product.

2. System Components

A complete Laser Wire® system consists of four component types:

Component	Function	Notes
Source Module	Laser or high-brightness LED that injects light into the fiber end	Capsule Module (single fiber), DMX Module (RGB + dimming), OpalDrive (multi-fiber)
Fiber Strand	Side-emitting plastic optical fiber — the visible light element of the system	Multiple diameters; standard and Prism variants; sold by the meter
Patch Cables	Pre-terminated fiber segments with connectors at both ends	Used for module-to-fiber connection and for systems requiring field connector joints
Power Supply	DC power to the source module; voltage is module-dependent	12V or 24V DC depending on module type; see power planning section

3. Fiber Profiles

Standard Laser Wire®

The standard fiber profile is a single-layer construction: side-emitting PMMA core with a UV-stabilized outer jacket. Available diameters: 0.75mm, 1.0mm, 1.5mm, 2.0mm, 3.0mm. The 1.5mm diameter is the most commonly specified for general architectural and display applications — it provides sufficient emission output for most environments while routing through tight channels and bends.

Laser Wire® Prism

The Prism variant uses a dual-layer construction with a prismatic outer jacket that increases side emission output by approximately 40% over standard fiber at the same diameter. Prism fiber is specified for applications where the viewing distance is greater than 3 meters, or where the installation environment has competing ambient light that standard fiber emission doesn't overcome.

Prism is available in the same diameter range as standard fiber but at a higher cost per meter. For most indoor architectural applications, standard fiber is sufficient; Prism is typically specified for large-scale installations, high-ceiling environments, and any application where brightness is the primary driver. See our Prism vs Standard comparison for a full application-by-application guide.

4. System Limits

Parameter	Standard Fiber	Prism Fiber	Notes
Max single-source run	15m	12m	Beyond this, brightness falloff at far end becomes visible. Inject from both ends for longer runs.
Min bend radius (1.5mm)	25mm	30mm	Tighter bends create a bright spot at the bend point and risk fracturing the core.
Min bend radius (3.0mm)	50mm	60mm	Larger diameter = larger minimum bend radius. Plan channel routing accordingly.
Operating temperature	−20°C to +60°C	−20°C to +55°C	Sustained operation above 55°C (Prism) or 60°C (standard) will accelerate jacket degradation.
Fibers per DMX module	1 (standard output) or up to 4 (split with fiber splitter accessory)		Splitting reduces output per fiber proportionally. Use for short runs at close viewing distance.
Fibers per OpalDrive	Up to 6 (dedicated output per fiber)		Each output is independently dimmable. OpalDrive is the correct choice for multi-zone installations.

5. Modules & Control Options

Capsule Module

The Capsule Module is a fixed-color, fixed-brightness source. It accepts a single fiber strand, and the output color is determined at manufacturing time by the laser wavelength or LED emitter color specified at order. No controller is required — connect DC power and the module is on.

Specify the Capsule when: the installation is fixed single-color and dimming or color change is not required. The Capsule is smaller, lower-cost, and simpler than the DMX module for static applications. Full specs: Capsule Module Spec Sheet.

DMX RGB Module

The DMX Module provides full RGB color mixing and dimming control over DMX-512. Each module occupies 3 DMX channels (R, G, B) and can be addressed independently. Use the DMX module when any of the following apply: color must be changeable after installation, dynamic color effects are required, or the installation is part of a larger DMX-controlled system.

The DMX module requires a DMX controller and a DMX data line (XLR cable or DMX-over-Cat5 adapter) in addition to DC power. The module self-terminates if it is the last device in the DMX chain. Full specs: DMX RGB Module Spec Sheet.

OpalDrive

OpalDrive is a multi-channel source driver for installations requiring multiple fiber zones from a single controller point. Each OpalDrive unit drives up to 6 independent fiber outputs, each independently dimmable and color-controllable. OpalDrive uses its own control protocol (not DMX) and ships with a dedicated app for setup and programming.

OpalDrive is the correct specification for larger installations — hospitality environments, permanent architectural installations with multiple zones, or any installation where individual zone control is required without per-zone DMX addressing overhead. Details: OpalDrive Product Guide.

6. Power Planning

Module	Input Voltage	Current Draw	Max Load per Supply
Capsule Module	12V DC	280mA max	Up to 12 modules on a 5A 12V supply (with 20% headroom)
DMX RGB Module	24V DC	480mA max (full white)	Up to 8 modules on a 5A 24V supply (with 20% headroom)
OpalDrive (per unit)	24V DC	Up to 3.2A (6 outputs at full)	One 5A 24V supply per OpalDrive unit (with 20% headroom)

Design rule: Always size power supplies to 80% of rated capacity. A 5A supply should carry no more than 4A of load. This provides thermal headroom and accounts for inrush current at startup.

Cable run limitations: 12V systems require larger wire gauge for long supply cable runs than 24V systems for the same load. For supply runs longer than 10m, use 24V modules if available, or upsize supply cable to 14AWG minimum for 12V systems.

7. Installation Notes

Cutting the Fiber

Laser Wire® fiber must be cut with a sharp, flat-edged tool — a dedicated fiber cleaver or a fresh single-edge razor blade. A clean perpendicular cut is required for maximum light injection at the source module end. An angled or ragged cut reduces the effective aperture and produces a bright spot at the cut end rather than uniform emission from the source module injection point.

After cutting, lightly sand the cut face with 400-grit then 800-grit sandpaper and wipe clean before inserting into the module. The polished cut face maximizes light coupling efficiency. Our detailed cutting procedure: How to Cut & Connect Laser Wire®.

Channel Routing

Laser Wire® fiber can be routed through virtually any channel that maintains the minimum bend radius — aluminum extrusion channels, routed grooves in wood or MDF, silicone tubing, or woven into textile backing. Key routing guidelines:

• Allow 5–10% slack at both ends for service access to the source module.
• Secure the fiber at intervals no greater than 300mm to prevent sagging in horizontal runs.
• In channel installations, use a light drag-fit — do not compress the fiber against the channel wall. Compression creates bright spots at the compression point.
• Where the fiber exits a channel or structure, protect the exit point from abrasion with a silicone grommet or soft-edge chamfer.

Welted Profile Installation

For upholstery, seating, and soft-goods applications, Laser Wire® is available pre-installed in a welted profile — a fabric-covered piping that can be sewn into seams, tufts, or edges using standard upholstery techniques. The welt integrates the fiber and provides a clean, professional finish without exposed fiber. Details: Welted Profile Guide.

8. Design Examples

Example A: Hotel Lobby Cove (Single-Color, Fixed)

A 45m perimeter cove in a hotel lobby atrium. Requires continuous, dot-free glow in 3000K warm white with no active control.

Specification: 3× 15m runs of 2.0mm standard Laser Wire® (warm white); 3× Capsule Modules (3000K); single 5A 12V supply per module on a dedicated circuit; aluminum V-profile channels routed into the cove reveal.

Power budget: 3 modules × 280mA = 840mA total. One 2A 12V supply covers the full installation with significant headroom; or three individual 5V USB power adapters (one per module) for the lowest-cost power approach.

Example B: Nightclub Bar Edge (Dynamic RGB, DMX)

A 24m bar edge in a nightclub environment requiring full-color dynamic effects synchronized to a lighting console.

Specification: 2× 12m runs of 1.5mm Prism Laser Wire® (RGB); 2× DMX RGB Modules addressed at DMX 001 and DMX 004; connected to venue lighting console via XLR DMX cable; single 5A 24V supply per module on independently switched circuit.

Power budget: 2 modules × 480mA = 960mA at full white. One 2A 24V supply handles both modules. At typical operating levels (60–70% RGB output), the actual draw is approximately 580mA.

Example C: Automotive Cabin Accent (Multi-Zone)

Interior cabin accent lighting in a high-end vehicle build: door sills, dashboard reveal, and seat base (six independent zones).

Specification: 6× 2m runs of 0.75mm standard Laser Wire® (single-color per zone); 1× OpalDrive unit (6 outputs); 5A 24V automotive-grade power supply with inline 3A fuse per output; all fiber routed through factory channels with added silicone grommets at entry points.

Power budget: OpalDrive maximum 3.2A at 24V. Six zones each driving 2m of 0.75mm fiber draws approximately 100mA per zone = 600mA total. Significant headroom on the supply; size to 1A for this application.