Introduction: 3D Printed on Air Sign With Flashing LEDs and CNC Milled Circuit Board

Picture of 3D Printed on Air Sign With Flashing LEDs and CNC Milled Circuit Board

This On Air Sign with Flashing LED lights was 3D printed and also has a CNC milled circuit board I created on a X-Carve machine. No micro or Arduino required.

Step 1: Video

A full video of the steps are available at my YouTube Channel.

Step 2: Circuit

Picture of Circuit

No microcontroller or Arduino was needed because I used an Astable Multivibrator circuit that only needed two NPN transistors, two capacitors, four resistors and two LEDs. Also a switch and 9v battery were added.

Step 3: Circuit Board Design

Picture of Circuit Board Design

I used ExpressPCB to make the circuit board. There are lots of other options.

Step 4: Copper Connection

Picture of Copper Connection

I used Copper Connection board layout software to import the ExpressPCB file and output a set of Gerber Files for the board.

Step 5: Bottom Layer

Picture of Bottom Layer

I used Flatcam software to load the bottom layer of the board (which was single sided) to create the GCode for the X-Carve CNC.

Step 6: Drill File

Picture of Drill File

I use Flatcam to also create the drill file GCode from the Gerber drill file.

Step 7: Milling Traces

Picture of Milling Traces

Universal GCode Sender software was used to control the X-Carve CNC. The GCode for the Bottom Layer was loaded and then sent to the X-Carve controller.

Step 8: Milling Traces Part 2

Picture of Milling Traces Part 2

I used a 20 degree engraving bit to cut the isolation channels that form the traces in the single sided copper board.

Step 9: Drilling Holes

Picture of Drilling Holes

Universal GCode sender was used to send the drill file to the X-Carve.

Step 10: Drilling Holes Part 2

Picture of Drilling Holes Part 2

I used a 0.035" drill bit for the holes.

Step 11: Electrical Test

Picture of Electrical Test

I sanded the top of the board with sandpaper and then checked for shorts with an ohm meter. The traces were good.

Step 12: Components Inserted

Picture of Components Inserted

The components were inserted and the leads bent to hold them in place.

Step 13: Soldering

Picture of Soldering

The copper soldered easily with typical rosin core solder. All excess leads were clipped.

Step 14: Testing

Picture of Testing

The board was powered up and the circuit worked perfectly. The LEDs were soldered on the opposite side to fit in the 3D Printed case.

Step 15: 3D Printed Case

Picture of 3D Printed Case

A 3D printed case was designed in Tinkercad and shared on Thingiverse. The design has a 9v battery holder and holes for a switch and the two flashing LEDs.

http://www.thingiverse.com/thing:1705206

Step 16: Assembly

Picture of Assembly

The board was wired to a switch and 9v Battery clip. The case was completed on my FlashForge 3D printer. Everything ready for assembly.

Step 17: Final Assembly

Picture of Final Assembly

The battery fit in the designed bracket perfectly and the board was held in place with double sided foam sticky tape. The switch was held in place with a nut.

Step 18: Finished

Picture of Finished

The finished design is assembled and ready to use. Works great to warn family I'm filming my YouTube Video.

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