I have had a lot of interest in this project from a lot of quarters. It is actually moving along pretty well. I am in my China office from next Wed for 5 weeks and I already have one of my staff set aside to spend most of that time with me on this project. They have made appointments at LED manufacturers, plastic injection mould making factories and LED assembly plants.
The first step in this project is to have the LEDs manufactured to my specs. Then comes the plastic frame. After that it will come together fairly quickly. Despite what a lot think, things move pretty slowly in China.
Here are some 'teaser' engineering drawings of the plastic frame and the LEDs (they may not represent the finished product and certain 'sensitive' info removed):
