Working on a large spherical LED screen project right now, and honestly it feels very different from flat displays.
At first we thought installation would be the hardest part, but once modules start going up, small alignment and curvature differences become really obvious. On the other hand, structure and on-site adjustment also get tricky as the diameter grows.
So I’m curious how this plays out in real projects:
In your experience, what usually causes more problems — manufacturing accuracy or installation and on-site calibration?
And if you had to do it again, where would you spend more effort upfront?
We worked on a fairly large spherical screen project last year, and from my experience, both sides can cause issues — but module consistency is usually where problems show up first.
Everything looked fine during factory checks, but once the modules went onto the sphere, small differences in curvature and alignment became much more obvious. On site, you can adjust and compensate to a point, but it’s hard to completely hide those deviations.
Installation definitely isn’t easy either, especially as the diameter increases. Structural stiffness and adjustment range matter a lot. That said, if the modules are already off, installation can only do so much.
If I had to do it again, I’d probably spend more effort locking down module accuracy upfront and treat installation mainly as fine-tuning.