Aurora Builder Series | ScreenBuilder, FrameBuilder & AutoPCB

Aurora Builder Series

Three Tools. One Integrated LED Design Pipeline.

From screen configuration to structural engineering to PCB automation — Aurora's Builder Series is a vertically integrated software suite that takes LED display projects from concept to manufacturing-ready output.

ScreenBuilder

FrameBuilder

AutoPCB

Design Pipeline

How the Builder Series Works Together

ScreenBuilder

Design & configure LED screens, optimise cabinets, generate quotes

FrameBuilder

Generate structural steel frames, FEA analysis, foundation design

AutoPCB

Import module grids, auto-generate PCB layouts, export to KiCad

ScreenBuilder

The complete LED screen design and quoting platform. Configure flat, curved, hybrid, and creative displays with intelligent cabinet optimisation, real-time 3D preview, and automated BOM generation.

Web Application Multi-Region AI-Powered

Core Capabilities

Wizard-Driven Configuration — Step-by-step setup for application type (indoor/outdoor), location, viewing distance, and target dimensions
Intelligent Cabinet Optimizer — Mixed-cabinet solutions using greedy bin-packing algorithm to achieve zero dimensional error with the fewest cabinets
4 Screen Design Modes — Flat (standard rectangular), Curved (single radius), Hybrid (mixed straight + curved segments with right-angle corners), and Creative (3D model import)
Interactive 3D Preview — Real-time Three.js visualisation of individual cabinets, full screen arrays, and cabinet grids with content overlay
Automated BOM Generation — Complete bill of materials including cabinets, modules, processors, receiving cards, signal/power cables, mounting hardware, and spare parts
Processor Selection Wizard — AI-driven recommendation engine matching pixel load, output requirements, and budget to the optimal video processor
H Series Frame Builder — For screens exceeding 10M pixels, a specialised configurator for Novastar H series modular video processors with input/output card selection
Multi-Screen Project Mode — Manage multiple screens within a single project with per-screen service costs, shared frames, and aggregated pricing
Professional PDF Export — Technical quotes with topology diagrams, power distribution maps, size comparisons, tax calculations, and currency conversion
Multi-Regional Pricing — AU (AUD) and Export (USD) sales regions with automatic currency conversion and region-specific tax handling

40+

Cabinet Models

Design Modes

Tax Regions

Live Preview

ScreenBuilder calculator interface showing cabinet selection, optimised cabinet matching, LiDAR scanner integration, and guided wizard workflow

ScreenBuilder — Calculator with 3D preview and cabinet optimisation

Hybrid Curved Screen 3D Viewer showing immersive curved LED display with module grid, human figure for scale, content overlay, and export tools

ScreenBuilder — Curved and hybrid screen design with top-view layout

FrameBuilder

Parametric structural steel frame generation for LED displays. Automatically sizes steel profiles, calculates wind and dead loads to Australian standards, and exports manufacturing-ready 3D models and STEP files.

FrameBuilder — Parametric steel frame with legs and footings

FrameBuilder Frame Configurator interface showing screen dimensions, cabinet array settings, wind zone selection (AS/NZS 1170.2), mounting type, and structural results panel

FrameBuilder — Multi-format export: GLB, STEP, and engineering PDF

Microservice CadQuery AS/NZS

Engineering Features

Parametric Frame Generation — CadQuery-based 3D modelling creates steel frames automatically sized to any cabinet array dimensions
Wind Load Analysis — AS/NZS 1170.2 compliant wind action calculations with configurable terrain category, shielding, and topographic factors
Steel Design — AS 4100 structural steel design with automatic SHS profile selection based on combined bending, shear, and axial loads
Foundation Design — AS3600-2018 compliant pad footings and bored pier calculations with soil bearing capacity checks
Multi-Format Export — GLB files for web 3D preview, STEP files for CNC manufacturing and detailed engineering drawings
API-Driven Architecture — Runs as an independent microservice, accepting screen dimensions via REST API and returning generated models
Cabinet Catalog Integration — Imports the full cabinet catalog from ScreenBuilder's API for accurate sizing, with built-in fallback data for 40+ models
Walkway and Access — Automatically generates FRP flooring, handrails, hatches, and maintenance access platforms for elevated installations

AS/NZS Standards

GLB

+ STEP Export

40+

Cabinet Models

REST

API Driven

AutoPCB

AI-powered PCB design automation for LED modules. Imports module grid data from ScreenBuilder, automatically generates PCB layouts with driver IC selection, and exports manufacturing-ready files in KiCad and Gerber formats.

AI-Powered KiCad Export Automated

PCB Automation Pipeline

ScreenBuilder Import — Browse and import screen designs directly from ScreenBuilder via the external API, including full module grid data with 3D coordinates and surface normals
Module Grid Processing — Parses precise X/Y/Z positions, rotations, curvature radii, and surface normals for every LED module in the layout — including curved and hybrid screens
AI-Driven PCB Layout — Automatically generates multi-layer PCB designs for each unique module type, with optimised LED placement, driver IC routing, and power distribution
Driver IC Selection — Intelligent constant-current LED driver selection based on pixel pitch, LED count, PWM requirements, and thermal constraints
Curved Surface Support — Handles flexible PCB designs for curved modules with curvature-aware trace routing and stress analysis
Multi-Module Projects — Manage complex installations as a single project with per-module PCB specs, shared BOM, and assembly documentation
Manufacturing Export — KiCad project files, Gerber/drill files, pick-and-place data, and component BOM for direct handoff to PCB fabrication houses
3D Model Preview — Downloads and renders the GLB model from ScreenBuilder with module grid overlay for visual verification before PCB generation

Layout Engine

API

ScreenBuilder Link

Multi

Layer PCBs

KiCad

+ Gerber Export

AutoPCB interface showing star-shaped LED module PCB design with 474 LEDs, driver IC selection, rule validation, BOM, and performance panels

AutoPCB — LED module array with driver IC placement and trace routing

AutoPCB Screenbuilder Catalog showing 179 LED cabinets and 59 processors with filters, expanded cabinet details including dimensions, module info, and performance specs

AutoPCB — ScreenBuilder API import to automated PCB generation

Developer Integration

Connected via API

The Builder Series tools communicate through a secure REST API, enabling real-time data exchange between screen design, structural engineering, and PCB automation.

ScreenBuilder External API

Provides screen design data and module grids to FrameBuilder and AutoPCB

GET /api/external/catalog/cabinets

GET /api/external/screen-designs

GET /api/external/screen-designs/:id

GET /api/external/screen-designs/:id/model

FrameBuilder Microservice API

Generates structural frames from screen dimensions and returns 3D models

POST /api/generate-frame

GET /api/health

Module Grid Data Structure

The module grid is the critical data bridge between ScreenBuilder and AutoPCB. Each entry contains precise 3D coordinates, rotation, curvature, and surface orientation for every LED module in the layout.

{
  "moduleIndex": 0,
  "moduleModel": "M2.5-160x160",
  "positionX": 0, "positionY": 0, "positionZ": 0,
  "rotationDeg": 0,
  "curvatureRadius": null,
  "widthMm": 160, "heightMm": 160,
  "pixelPitchMm": 2500,
  "pixelsX": 64, "pixelsY": 64,
  "moduleType": "standard",
  "surfaceNormal": { "x": 0, "y": 0, "z": 1 }
}

Data Flow

What Moves Between Systems

ScreenBuilder Output

Produces complete screen configurations with optimised cabinet arrays, module grid coordinates, 3D models, and full BOM pricing. This data feeds both FrameBuilder and AutoPCB.

screenWidth 4500mm

screenHeight 2500mm

cabinetModel AX1.9-I

totalPixels 5.9M

moduleGrid[] 360 items

glbModel binary

FrameBuilder Output

Generates parametric steel structures with AS/NZS engineering calculations. Returns 3D preview models and manufacturing-ready STEP files for CNC fabrication.

frameGlb 3D model

frameStep CNC ready

windLoad 1.2 kPa

steelProfile SHS 75x75

footing 600x600mm

weight 185 kg

AutoPCB Output

Transforms module grid data into complete PCB designs with driver IC selection, LED placement, trace routing, and manufacturing files for each unique module type.

kicadProject .kicad_pcb

gerberFiles .gbr zip

driverIC ICN2153

layers 4-layer

bom CSV

pickPlace SMT data

Build Better LED Displays, Faster

From screen configuration to structural steel to PCB layout — the Aurora Builder Series automates the entire LED display engineering pipeline.

Three Tools. One Integrated LED Design Pipeline.

ScreenBuilder

FrameBuilder

AutoPCB

ScreenBuilder

Core Capabilities

FrameBuilder

Engineering Features

AutoPCB

PCB Automation Pipeline

ScreenBuilder External API

FrameBuilder Microservice API

Module Grid Data Structure

ScreenBuilder Output

FrameBuilder Output

AutoPCB Output

Build Better LED Displays, Faster

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