I need to design a LED module something similar to below.
Could anyone who is experience tell me if there is any SW (or tools) to determine how to place the LEDs to have a good and evenly distributed light output, and a SW to simulate the thermal behavior and decide how far they should be replaced from each others? If there is no SW for it, what are the thumb of rules to determine distances of the LEDs from each others (especially if all are not the same color LEDs)?
Second question, I have never done any design than FR4 board. What are the standards on aluminum boards (aluminium thickness, copper thickness, solder finish, etc). What Gerber files do I need to send to a factory (top layer, top silkscreen, holes, top solder paste, anything else)?
What are the considerations while preparing such module? Obviously all should be routed in a single layer. Is it good to have a ground layer for the unused area or is it better to etch and have aluminium to have a better thermal performance?
Do you have any suggested reference/document/application note to read to design LED module on aluminium board?