How an Aurora cabinet is built — every step, every checkpoint.
Aurora cabinets are designed, engineered and manufactured by Aurora Display Technologies Limited, the group's HK production entity, then re-inspected on landing in Australia before they go anywhere near a job site. This is the 22-step process, with the 6 independent QA checkpoints called out — same sequence we run for every cabinet, regardless of project size.
- Process steps
- 22
- QA gates
- 6
- Phases
- 5+1
Materials in
Every component lot is logged at the gate and checked against the bill of materials before it can be released to the line.
- 1
Materials received
原材料进厂LEDs, driver ICs, PCBs, power supplies, cabinet steel and finishing components are received against the purchase order, batch-coded and routed to the bonded inbound area.
- 2
IQC — Incoming material inspection
QA gate IQC来料检验Incoming Quality Control samples each lot against the engineering spec — LED bin codes, IC datecodes, PCB impedance and finish, power-supply load test. Out-of-spec lots are quarantined and returned to the supplier.
Module electronics
Surface-mount and through-hole assembly of the LED modules and driver boards, followed by burn-in and weather-proof coating before they ever see a cabinet.
- 3
SMT placement
SMT贴片Surface-mount LEDs and driver ICs are placed on the module PCB by automated pick-and-place lines. Solder paste is reflow-cured under a controlled thermal profile matched to the LED package class (3535 / 2727 / 2121 / 1010).
- 4
DIP soldering
DIP焊接Through-hole connectors and the high-current sections of the receiver card are wave-soldered and inspected for joint integrity.
- 5
PCBA burn-in
PCBA老化Populated boards run a 24-hour burn-in cycle at elevated temperature with the receiver card driving a known signal pattern. Boards that exhibit infant-mortality failure are pulled before they enter cabinet assembly.
- 6
Three-proof conformal coating
三防涂覆Modules destined for high-humidity, marine or coastal installs are coated with a moisture-, dust- and salt-resistant conformal layer. The coating is UV-cured and inspected under UV light for full coverage.
Cabinet build
Modules are dressed into cabinets — kit, cover, full-cabinet QC, then mechanical cabinet assembly — and queued for system integration.
- 7
Kit assembly
装套件Modules, receiver card, hub board, power supplies and internal harness are dressed into the module cassette per the cabinet drawing.
- 8
Front mask install
装面罩Module front masks (the customer-visible LED-pixel mask) are aligned and seated. Pixel-pitch measurement is taken at this stage; out-of-tolerance modules are reworked, not shipped.
- 9
QC full inspection
QA gate QC全检Every cabinet module passes a full optical and electrical inspection: pixel uniformity, dead-pixel count against the Aurora threshold, brightness distribution, and refresh rate above the 3,840 Hz broadcast floor for camera-facing builds.
- 10
Cabinet mechanical assembly
箱体组装Modules are mounted into the cabinet shell. Locks, hinges, magnetic alignment pins and rear service panel are torqued to spec.
- 11
Cabinet in-plant logging
箱体进厂Every assembled cabinet is barcoded, photographed and logged into the production MES against its serial number, build date and owning project.
- 12
IQC — Cabinet inspection
QA gate IQC检验A second IQC checkpoint validates the assembled cabinet against the engineering drawing — backbone dimensions, frame squareness, door fit, handle and lock positions, screw-thread placement.
Wall-up & calibration
Cabinets are tiled into the customer wall configuration and run as a system — calibrated, safety-tested and aged — before anything is packed.
- 13
Safety / regulatory test
QA gate 安规测试Hi-pot, earth-bond and leakage-current tests against AS/NZS 62368 (electrical safety) and CISPR 32 (EMC emissions). Results are recorded against each cabinet serial for the RCM compliance file.
- 14
Single-point pixel calibration
单点校正Every pixel on every module is measured for brightness and chromaticity, and a per-pixel correction LUT is written to the receiver card. This is what allows an Aurora wall to look uniform across cabinets at install — not just within them.
- 15
Large-screen assembly
大屏拼装The full customer wall is tiled in the QA bay, exactly as it will be installed on site. Cabinet seams, brightness joins and colour uniformity are inspected as a system, not as individual cabinets.
- 16
System debug & ageing
调试老化The assembled wall runs a 72-hour ageing cycle with the customer's actual processor and source signal. Any signal-chain, brightness-curve or scaling issues are caught here, not on site.
Pack, store, ship
Final outbound QC, project-specific packaging and bonded warehousing prior to dispatch. Australian-bound stock is then re-inspected on landing in Adelaide before any cabinet leaves for site.
- 17
OQC — Outgoing quality control
QA gate OQC检验A final outbound check by an inspector independent of the production line: cosmetic finish, accessory completeness, documentation pack, RCM marking and serial-number reconciliation against the project bill of materials.
- 18
Project-specific packaging
成品包装Cabinets are foam-cradled into project-specific flight cases or export crates with cabinet-position labels matching the install drawing — so the install crew can unpack to the wall sequence rather than shuffling on site.
- 19
Bonded warehousing
入库Crates are scanned into the bonded export warehouse pending shipment. The same MES record follows the cabinet from gate to dispatch.
What Aurora adds on landing.
The handover step that separates Aurora-supplied cabinets from offshore drop-ship. Every shipment is re-inspected on Australian soil before any cabinet is released to a job site.
- 20
AU receiving inspection
QA gate 到澳洲质检Every shipment into Australia is re-inspected on landing at the Marleston, SA head office: crate-condition photos, serial-number reconciliation, sample power-on test and AS/NZS compliance pack archived against the project file before any cabinet is released to the install crew.
- 21
Aurora install & commissioning
现场安装Aurora-employed install crews wall up the screen on site, run on-wall calibration against ambient conditions, and commission with the customer's processor and content stack. Sign-off is witnessed by the customer before handover.
- 22
Local service contract
本地服务网络Spares are stocked in Adelaide and Melbourne with dispatch hubs in QLD and WA. Warranty work is dispatched from the Australian-stocked spares pool — no offshore parts queue, no shipping wait.
Same 22 steps, every cabinet.
Aurora cabinets are MES-tracked from the inbound bonded area through to Australian dispatch. The build record — IQC results, burn-in pass, QC inspection, calibration LUT, hi-pot test, OQC sign-off and AU receiving inspection — is archived against the project file so procurement teams have a documented trail to audit. The 6 QA checkpoints in this process are the documented stages where production can stop and rework before a cabinet progresses.
Aurora's engineering team will walk you through the build record for the cabinets in your spec.