Handmade LED Cube Is A Work Of Art

September 5, 2019 by Lewin Day 18 Comments

We see all kinds of projects come across the news desk at Hackaday. Sometimes it’s a bodge, neatly executed, that makes us laugh out loud at its simple ingenuity. Other times, it’s a case of great skill and attention to detail, brought to bear to craft something of great beauty. [Greg Davill]’s LED cube is firmly the latter.

The matte black finish makes the artwork really pop. Note the matrix of tiny pads for the LEDs on the backside.

The build starts with custom four layer PCBs, in matte black with gold-plated pads. It’s a classic color scheme, and sets the bar for the rest of the project. Rather than proceeding to hook up some commodity microcontrollers to off-the-shelf panels, [Greg] goes his own way. Each PCB gets a 24×24 raw LED matrix, directly soldered on the back side. By producing a “dumb” matrix, there are large savings in current draw to be had over the now-popular smart strings.

The panels are then loaded into a tidy 3D printed cube, with space inside for the FPGA running the show and a power supply. Five panels are held in with double sided-tape and screws, with the last being installed with magnets to allow access to the inside. Neatly folded flat-flex cables are pressed into service to connect everything up.

It’s a build that shows there is value in doing things your own way, and that the new methods don’t always beat out the old. With careful consideration of aesthetics from the start to the end of the project, [Greg] has built an LED cube both astounding in its simplicity, and beautiful in its execution. We’ve seen [Greg]’s work before, too – it’s not too often hand soldered BGAs cross these pages. Video after the break.

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This LED Cube Is One Heck Of An ICEBreaker

September 5, 2019 by Lewin Day 7 Comments

Like the tastes of the makers that build them, LED cubes come in all shapes and sizes. From the simplest 3x3x3 microcontroller test, to fancier bespoke installations, they’re a great way to learn a bunch of useful embedded techniques and show off at the same time. [kbob] has done exactly that in spades, with a glittering cube build of his own and published a repository with all the files.

Just like a horde of orcs from Mordor, [kbob]’s cube is all about strength in numbers. Measuring 136 mm on each side, it’s constructed out of 64 x 64 P2 panels, packing 4096 LEDs per side, or 24,576 total. A Raspberry Pi is used to run the show, allowing a variety of animations to be run. Unfortunately, it lacks the raw horsepower to run this many LEDs at a decent frame rate. Instead, it’s teamed up with an ICEBreaker FPGA, which can churn out the required HUB75 signals for the panels without breaking a sweat.

Thanks to the high density of tiny LEDs, and the smooth framerate of the animations, the final effect is rather gorgeous. [kbob] notes that there’s actually a lot of people working on similar projects with ICEBreaker muscle; a recent video from [Piotr] is particularly impressive.

The LED cube will likely remain a staple for sometime, and we can’t wait to see what comes out next from the community. You can even throw in some OpenGL if you wanna get fancy. Video after the break.

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Faux-Neon Sign Says What?, Auf Deutsch

September 2, 2019 by Ted Yapo 11 Comments

To a speaker of English, a sign asking ‘Was?” may not make much sense. In German, however, the question is a more thought-provoking “What?” That’s exactly the point of this faux-neon sign created by [noniq]. The sign uses silicone-enclosed “neon-like” LED strips to spell out the question for all to see — and ponder.

While true neon aficionados will bristle at even calling such LED strips “faux neon” (check the comments below for examples), we really like them for sign projects like this. They’re great-looking, inexpensive, easy to work with, and available with RGB LEDs for variable colors. In this case, they were mounted on 3 mm polystyrene plate glued to a wooden frame made from 22 mm square beams.

One of the things that caught our eye about this build is the use of a CNC mill to create a prototype. With the strokes milled out of a foam board, the final effect could be visualized before committing to the design. This board later served as a template for cutting the LED strips to length — clever! We suspect this could also be done with a hobby knife and a liberal dose of patience by those without access to a CNC mill.

Of course, this type of project doesn’t always turn out perfect the first time. The sign was missing a dot for the question mark, light leakage from ends of the individual segments was creating distracting bright spots on the base, areas where the silicone had been removed to connect the LEDs were noticeably darker, and the letters looked too thin. We’re looking forward to the promised second post, in which [noniq] describes the solution to these issues.

This isn’t the first time we’ve seen these LED strips used for sign-making, like in this logo build last Spring.

Giant LED Display Is 1200 Balls To The Wall

August 29, 2019 by Dan Maloney 10 Comments

When you’re going to build something big, it’s often a good idea to start small and work out the bugs first. That’s what [bitluni] did with his massive 1200-pixel LED video wall, which he unveiled at Maker Faire Hanover recently.

We covered his prototype a while back, a mere 300 ping pong ball ensconced-LEDs on a large panel. You may recall his travails with the build, including the questionable choice of sheet steel for the panel and the arm-busting effort needed to drill 300 holes with a hand drill. Not wanting to repeat those mistakes, [bitluni] used the custom hole punch he built rather than a drill, and went with aluminum sheet for the four panels needed. It was still a lot of work, and he had to rig up some help to make the tool more comfortable to use, but in the end the punched holes appear much neater than their drilled counterparts.

[bitluni] mastered enough TIG welding to make nice aluminum frames for the panels, making them lightweight and easy to transport. 1200 ping pong balls, a gunked-up soldering iron, and a package of hot glue sticks later, the wall was ready for electronics. It took a 70-amp power supply and an ESP32 to run everything, but that’s enough horsepower to make some impressive graphics and even stream live video – choppy and low-res, but still usable.

We love the look this wall and we appreciate the effort that went into it. And it’s always good to see just how much fun [bitluni] has with his builds – it’s infectious.

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Lead Former Makes LED Cubes A Little Easier To Build

August 25, 2019 by Dan Maloney 8 Comments

There’s no doubting the allure of a nicely crafted LED cube; likewise, there’s no doubting that they can be a tremendous pain to build. After all, the amount of work scales as the cube of the number of LEDs you want each side to have, and let’s face it – with LED cubes, the bigger, the better. What to do about all that tedious lead forming?

[TylerTimoJ]’s solution is a custom-designed lead-forming tool, and we have to say we’re mighty impressed by it. His LED cubes use discrete RGB LEDs, the kind with four leads, each suspended in space by soldering them to wires. For the neat appearance needed to make such a circuit sculpture work, the leads must be trimmed and bent at just the right angles, a tedious job indeed when done by hand. His tool has servo-controlled jaws that grip the leads, with solenoid-actuated lead formers coming in from below to bend each lead just the right amount. The lead former, along with its companion trimmer, obviously went through a lot of iterations before [TylerTimoJ] got everything right, but we’d say being able to process thousands of LEDs without all the tedium is probably worth the effort.

We’re looking forward to the huge LED cubes this tool will enable. Perhaps this CNC wire bender and an automated wire cutter would come in handy for the supporting wires?

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LED Triangle Looks Cool; Someone Tell Alt-J

August 24, 2019 by Lewin Day 7 Comments

For the average person, decorating at home is as simple as a few choice picks from the IKEA catalogue. Makers are a different breed, though – preferring something customized and glowing. This LED triangle is a particularly great example of the form, and the latest benchmark for excellence to come out of [scanlime’s] workshop.

Hailing from the recent past of 2014, it’s a design that is well-suited to the average makerspace. Built out of layers of lasercut chipboard and acrylic, it creates 16 seperate pockets for LEDs with very little bleed in between. A black bezel is fitted to complete the effect, along with frosted white acrylic diffusers for each triangle element.

The build uses WS2812B LEDs, controlled by [scanlime’s] Fadecandy controller. Fadecandy is a combination of hardware and software designed specifically for LED art projects, providing high-quality control of dithering and other effects to help make glowables prettier. It tends to turn up wherever head-turning visualizations are needed. In this application, it does a great job, with the pseudo-random flickering of the pixels being almost hypnotizing in nature.

It’s a great cyberpunk art piece, and we’d love to have one on our coffee table at home. If you’re sick of LED cubes, triangle-based builds may reignite your passion. Video after the break.

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Fail Of The Week: How Not To Light Pipe

August 19, 2019 by Dan Maloney 17 Comments

You’d think that something made out of glass and epoxy would transmit a decent amount of light. Unfortunately for [Jeremy Ruhland], it turns out that FR4 is not great light pipe material, at least in one dimension.

The backstory on this has to do with #badgelife, where it has become popular to reverse mount SMD LEDs on areas of PCBs that are devoid of masking, allowing the light to shine through with a warm, diffuse glow – we’ve even featured a through-PCB word clock that uses a similar technique to wonderful effect. [Jeremy]’s idea was to use 0603 SMD LEDs mounted inside non-plated through-holes to illuminate the interior of the board edgewise. It seems like a great idea, almost like the diffusers used to illuminate flat displays from the edge.

Sadly, the light from [Jeremy]’s LEDs just didn’t make it very far into the FR4 before being absorbed – about 15 mm max. That makes for an underwhelming appearance, but all is certainly not lost. Valuable lessons about PCB design were had, like exactly how to get a fab to understand what you’re trying to do with non-plated holes and why you want to fence the entire edge of the board in vias. But best of all, [Jeremy] explored what’s possible with Oreo construction, and came away with ideas for other uses of the method. That counts as a win in our book.