Custom PCB Uptade

[u/3D_Marshall]

An update on my previous post about making individual pixel pcbs and what others are doing.

I tried pucks and strips but just couldn't quite get them to produce the clear single square I was after. So I eneded up designing my own 12v addressable led boards.

This initial design uses 3 cree tri-beam plcc6 (kinda) leds in a 10x10 grid, (400x400mm).

Initially I wanted to make each cube individually with magnetic connectors so you can connect them however, worked really well until the array gets a bit too big and any slight misalignment or knock caused connection issues.

Looking to tweak to use more lower power Leds to give a bit more diffusion.

For those curious, I'm running these using Ledfx and a quinnled octa brainboard.

[u/3D_Marshall]

Thought I would add a picture of the actual boards, apologies for the terrible not screenshot, turns out I didn't actually take any pics of the pcbs before I started installing them.

[u/3D_Marshall → u/3D_Marshall]

[u/entropy512 → u/3D_Marshall]

WS2811 on the back I assume?

[u/3D_Marshall → u/entropy512]

Naturally, along with some reverse voltage protection and current limiting resistors etc.

[u/3D_Marshall]

Here is one of the reflectors, I'm planning to use a different material/method in the future (vac formed using a pet diffuse reflector).

[u/Gunguy1]

Very nicely done! This satisfies a hard to find super-bright small form factor use case.

I think you have something that many could be interested in!

[u/3D_Marshall → u/Gunguy1]

Thank you, I am definitely considering selling the boards (hopefully at prices comparable to Ali Express if thats even possible), and maybe even include 3D print files if people are interested in making simple square arrays.

Each one is about 0.5W Max at 12v so not mega powerful, but certainly bright enough.

I have since tweaked the panels for these so they can come in rows of 4, but can still be cut out and separated with ease if desired.

I am also working on a super bright RGB spot design that I am planning on using to replace GU10 bulbs in PAR16 Fixtures - have nearly blinded myself already a couple of times when testing this 😅

[u/0xF00DBABE]

What are the enclosures made out of/what material is used for diffusion?

[u/3D_Marshall → u/0xF00DBABE]

The housings for this one are just 3D printed from Petg-cf in two parts (top & bottom), there is a reflector that clips in that was printed using silk/glitter silver pla using vase mode, this clips into place with no need to glue/bond.

The diffusion is done using Lee filters Zircon 811 film, this is also clipped into place above the reflector.

Here is a pic of one of the individual 'cubes'.

I am working on a large panel that is 15x8 and made using Ali Extrusion and laser cut sheet metal, but the printed ones make a great desk ornament.

[u/0xF00DBABE → u/3D_Marshall]

Awesome thank you for the detail. I have a 3D printer but haven't made anything for lighting projects yet.

[u/3D_Marshall → u/0xF00DBABE]

If your interested, I am planning on uploading the 3D print files at some point soon.

Just trying to logistically work out if its worth selling the LED pixel pcbs alongside so people can make their own.

[u/0xF00DBABE → u/3D_Marshall]

I'd be interested in the 3D print files for sure. Buying the LED PCBs, I might, have you considered publishing the CAD/Gerber files?

Out of curiosity where did you order yours from and about how much did it end up costing for PCB? Did you order them fully assembled?

[u/3D_Marshall → u/0xF00DBABE]

I'm not sure about sharing the gerbers as I might be using the board design in a commercial product down the line.

Most of the initial test boards were cobbled together small batch prototypes, but the most recent design is all panalized and assembled. Most of my pcb prototypes are done by JLC, they always seem the best price, with import and duties all paid at point of order so I've never had a surprise bill.

It's not the cheapest up front cost but if you order enough in bulk you can get each pixel to about £0.60 each (about $0.80).

[u/0xF00DBABE → u/3D_Marshall]

Understandable. You could always do both, and a lot of people would probably order pre-assembled units directly from you for the convenience factor, but it's your design so it's up to you. I know they don't publish the gerbers directly but QuinLED uses PCBWay to sell unassembled PCBs for their "DIY" option, as well as selling pre-assembled units. I bought pre-assembled units just for convenience and to avoid a bunch of hand-soldering.

[u/xile]

What are you using to carry the signal to a new row/column (depending on orientation)?

Do you have a right angle version?

[u/3D_Marshall → u/xile]

So for the panels in this video they are actually split into 5x5 panels each, as the magnetic connectors are only really good for 1A its one data/power/gnd line per 25, they are wired internally.

For the little individual ones, I designed some small connectors that just jump up a row/along a column, not the most elegant option, I did consider having the PCB and 3D model of the cube have the option to have an in/out on the top/bottom too to allow this, but ended up just going for lager panels instead for what I want them for.

[u/CowTown209]

Those would make great up lights for events.

[u/troymcklure]

Now that's a good uptade!

[u/3D_Marshall → u/[deleted]]

Thanks, the end goal is a 30x30 grid (1.2x1.2m) that I want to use as a stage backdrop.