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The form factor — the shape and size of the circuit board — determines how many LEDs your module carries, how it mounts to a heatsink, and which optics fit. Choosing the right form factor is the first decision in any LED project. Start with the reference table below.
Quick Reference: All LED Module Form Factors
| Form Factor | LEDs | Size | Optic-Ready | Best For |
|---|---|---|---|---|
| Star | 1 | 20mm diameter | Yes (separate) | Flashlights, spot lighting, prototyping, compact fixtures |
| Tri-Star | 3 (series) | 20mm diameter | Yes (separate) | Higher output in a Star footprint, color mixing |
| 10mm Square | 1 | 10mm × 10mm | Yes (separate) | Tight spaces, linear arrays, machine vision |
| Rectangular | 1 | 10mm × 15mm | Yes (separate) | Linear strips, signage, edge-lit applications |
| 25mm Round | 1 | 25mm diameter | Yes (separate) | Standard fixtures, retrofit, general illumination |
| 25mm Square | 1 | 25mm × 25mm | Included (9°) | Focused spot lighting, accent lighting |
| Star/O | 1 | 25mm diameter | Included (various) | Plug-and-play with optic, simplified assembly |
| Quad | 4 (series) | 23mm diameter | Yes (separate) | High output, area lighting |
| 7-Up Round | 7 (series) | 40mm diameter | Yes (separate) | Maximum output per module, floodlighting, industrial |
| Side Emitter | 1 | 20mm diameter | Included (180°) | Edge lighting, cove lighting, wall grazing |
| Z 5mm Square | 1 | 5mm × 5mm | No | Ultra-compact, wearables, indicators |
| Z 10mm Square | 1 | 10mm × 10mm | No | Compact designs needing more output than Z 5mm |
| Z 20mm Quad | 4 | 20mm × 20mm | No | Compact high-output, color mixing with Z LEDs |
Single-LED Modules
The Star (20mm) is the most common form factor in the industry — 121 modules across all LED families and colors. It has the widest compatibility with third-party optics, heatsinks, and holders. If you are unsure where to start, start here.
The 10mm Square (121 modules) and Rectangular (33 modules) are compact form factors for tight spaces and linear arrays. The rectangular shape tiles end-to-end for strip lighting.
The 25mm Round (60 modules) has more copper area than the 20mm Star, so it spreads heat better. Common in retrofit fixtures where the 25mm footprint is standard.
Three form factors include a pre-installed optic, eliminating a separate optic purchase:
- 25mm Square (33 modules) — 9° narrow beam
- Star/O (60 modules) — various beam angles, round form factor
- Side Emitter (94 modules) — 180° side-emitting for cove and edge lighting. Light exits parallel to the mounting surface, not perpendicular.
Multi-LED Modules
These carry multiple LEDs wired in series on one board. More light per module, but the driver must supply a higher voltage (Forward Voltage adds up across LEDs in series).
- Tri-Star (3 LEDs, 20mm) — Same footprint as a single Star, 3× the output. 152 modules — the largest selection of any form factor. Also used for color mixing with three different wavelengths on one board.
- Quad (4 LEDs, 23mm) — Higher output than Tri-Star, slightly larger. 126 modules.
- 7-Up Round (7 LEDs, 40mm) — The highest-output standard form factor. A Neutral White Rebel ES 7-Up produces 1,610 lm at 700mA. 126 modules.
We also offer custom color mixing modules where you choose the LED colors for each position on a Tri-Star, Quad, or 7-Up board.
LUXEON Z Compact Modules
The LUXEON Z uses a smaller die than the Rebel. Z modules are physically smaller and are not compatible with Rebel-series optics.
- Z 5mm Square — The smallest module we offer. 35 modules.
- Z 10mm Square — Same footprint as Rebel 10mm Square, different LED. 29 modules.
- Z 20mm Quad — Four Z LEDs on a 20mm square board. 27 modules.
LED Families
Form factor and LED family are independent choices. Most form factors are available with multiple families.
| Family | Drive Current | Best For |
|---|---|---|
| LUXEON Rebel | 350mA | General white lighting. The workhorse. |
| LUXEON Rebel ES | 700mA | High-efficiency, maximum output per LED |
| LUXEON Rebel PLUS | 350mA | ANSI-binned white (2700K–5000K), tight color consistency |
| LUXEON Rebel Color | 350–700mA | Specific wavelengths: red, blue, green, amber, UV, IR |
| LUXEON Z | 350–500mA | Compact modules only (5mm, 10mm, 20mm) |
The product title tells you exactly what you are getting: “ANSI White (4000K), LUXEON Rebel PLUS LED on SABER 2 10mm Square Base, 103 lm @ 350mA” — color temperature, LED family, base technology, form factor, and rated output.
Base Technology
Most modules use our current-generation SABER 2 base (super-pillar aluminum MCPCB). Some are available on the older SinkPAD-II. Choose SABER 2 for new designs. See Module Series Comparison for details.
How to Decide
- How much light? Single LED enough? Star, 10mm Square, or 25mm Round. Need more? Tri-Star, Quad, or 7-Up.
- How much space? Tight: 10mm Square, Rectangular, or Z 5mm. Standard: Star or 25mm Round. Large: Quad or 7-Up.
- Need beam control? Star and 25mm modules have the widest optic selection. Or choose Star/O or 25mm Square with pre-installed optic.
- Light direction? Side Emitter for sideways. Everything else emits forward.
- Color? All form factors available in white and color. Check product listings for options.
- LED family? General white: Rebel or Rebel ES. Color-accurate white: Rebel PLUS. Specific wavelengths: Rebel Color. Compact: LUXEON Z.
You will also need a compatible LED driver and heatsink. If you need help, contact us or request a quote.
