Laser Wire® Systems · Installation
Welted Profile Installation Guide
The Laser Wire® Welted Profile is a specialty version of Laser Wire® cabling designed to be sewn into fabrics and textiles. It increases cabling durability, provides a robust sewing edge, and protects against kinking during installation and washing. V0.5.
What Is the Welted Profile?
The Laser Wire® Welted Profile is a specialty fiber specifically designed for sewing Laser Wire® cabling into fabrics and textiles. It increases the durability of the Laser Wire® cable while providing a robust but flexible sewing edge. It is perfect for costuming, Hollywood productions, marine, automotive, patio, and many other fabric applications. The Welted Profile is the easiest way to illuminate linear accents on textiles. The profile is strong enough to withstand multiple machine washings and will keep the wire from kinking or breaking.
The Welting consists of two parts: the Laser Wire® Cabling (the round section that glows) and the Sewing Area (the flat section that you stitch through). Only sew through the sewing area. Piercing through the cabling section can cause failure at the point where it is pierced.
Safety First
We are working with lasers. Just do not look directly at the laser diode or turn it on when it is not attached to the Laser Wire® cabling. When the Welting is trimmed, it can expose the Laser Wire® core. This core is sharp and can enter your skin — use caution. Make sure not to pinch the welted wire. This can break the core inside.
Items Required
- Laser Wire® Welted Cabling
- Laser Wire® Module (Capsule or OpalDrive)
- Fabric / Textiles
- Thread, Needle, or Sewing Machine
Installation Guide
Pro Tip: Map your path before you sew
Map out your welting route using shoelaces or flexible wire before making any cuts or stitches. Once the welting is sewn in, repositioning is difficult. Plan corners in advance — tight outside corners will need to be kerffed (notched).
1
Choose your application type
If you are lining a seat cushion, car seat, or more rigid surface, select a machine, needle, and thread robust enough to pierce through your material along with the additional plastic of the welting. If you are sewing into a garment, a machine will be infinitely easier than sewing by hand. Handle the product gently until it is fully installed — the odds of breaking the core are very low once it is sewn in securely.
2
Sew along the sewing area — not the cabling
When sewing the welting to your textile, sew along the surface in a straight line. Keep in mind the closer you get to the Laser Wire® cabling (the round section), the more likely it is that you will pierce and damage your welting. Sew through the sewing allowance only.
3
Handle corners: kerf to allow bending
If you are making angles around cushions or sides, you can cut (or kerf) the sewing area at the corners to allow the material to bend more freely. Do not cut all the way to the round portion of the welting, or you may cut through the wire. Leave about 1–2mm of space between your cut and the edge of the cable circle.
4
Manage the end of the run
Once you near the end, keep in mind the end of the fiber will emit all remaining light energy at once, creating a brighter spot at the tip. You can tuck this end into your fabric, poke it through a small hole and hide it on the inside, or apply a piece of black heat shrink to eliminate the light spillage entirely.
5
Connect the module and power on
Once sewing is complete, plug the laser module into the welting. Power on by plugging into a 5V source or pressing the button on an OpalDrive. The light starts right where the module connects. The laser module has a low-profile design to fit into pockets and cavities. Make sure minimum pressure is exerted on the Laser Wire® cabling at the connector — this is the most common reason for failure. Use extreme caution here.
DualDrive on Welted Profile
Adding a connector and laser module to the opposite end of the welting unlocks DualDrive mode. For instance, if a blue and green module are used on each end of the welting, it will give a gradient of the two modules inside the tubing, creating a teal-to-seafoam gradient. A red and green combination creates a yellowish-orange gradient. Red and blue creates a pink-to-purple gradient.
FAQ
Can Laser Wire® Welting be cut?
Yes. The wire continues to glow up to the point where it is cut. The cut end becomes brighter. Tuck the end inside the fabric or apply black heat shrink.
Do I need a controller?
No. The device operates at 5V DC. Any USB source providing at least 1A at 5V will work. USB Power Banks, cell phone chargers, USB wall adapters, even laptops. The OpalDrive module has its own internal battery, so once charged you are ready to go.
Can more than one Laser Wire® module be added to the Welting?
Yes. You can add more than one Laser Wire® module to allow for brighter results or color mixing. This is especially useful for color palettes by mixing the colors together.
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