Cutting out precise shapes requires a steady hand, a laser cutter, or a CNC mill, right? Nope! All you need is PCB design software and a fabrication facility that’ll do the milling for you. That’s the secret sauce in [bobricius]’s very pleasing seven-segment display design.
His Hackaday.io entry doesn’t have much detail beyond the pictures and the board files, but we’re not sure we need that many either. The lowest board in the three-board stack has Charlieplexed LEDs broken out to six control pins. Next up is a custom-routed spacer board — custom routed by the PCB house, that is. And the top board in the stack is another PCB, this one left clear of copper where the light shines out.
We want to see this thing lit up! We’ve played around with using PCB epoxy material as a LED diffuser before ourselves, and it can look really good. The spacers should help even out the illumination within segments, while preventing bleed across them. Next step? A matrix of WS2812s with custom-routed spacers and diffusers. How awesome would that be?