I came up with this idea a few years ago because I had a lot of scrap Lexan sitting around and I wanted to know what I could do with it. At the same time I was building a great many circuits and going through the expensive Radio Shack proto boards, wishing I had a cheaper alternative. Then I had the idea to solve the 2 problems with my left over Lexan pieces.
Step 1: Gather All the Supplies.
1. 1/8" Lexan sheet. (8x10 from Home Depot is only $3.89)
2. Circuit components (For this ible I only used 1 resistor and 1 Blue LED)
3. Tool for cutting Lexan. (Next to the Lexan at Home Depot)
4. Solder and solder iron.
5. Tape, glue, a lighter and candle.
(Notice my custom cardboard component holder) get it here https://www.instructables.com/id/Cardboard-Component-Storage/
Step 2: Ready the Lexan!
1. First score the Lexan where you want to make the cut. (Be careful the blade is sharp!)
A. To score the lexan put the bottom tip onto the Lexan surface and pull toward you. You should see little squiggle shaving come off the Lexan. If you try to use the tip top of the tool you won't get a good score on the Lexan.
2. After scoring the Lexan (I like to score both sides.)
3. Snap off the piece and you are ready to use the scrap Lexan. Be careful not to cut yourself or break the Lexan in the wrong spot.
4. Now that you have a small square to use as a circuit board you should decide what you want to do with the "Circuit board."
A. I wanted to make a pattern on the Lexan so it would light up when I attached a LED so this is what the additional score
lines are from.
Step 3: Circuit Design.
2. THIS STEP SHOULD BE PERFORMED OUTSIDE WITH GOOD VENTILATION. Now heat a needle (and hold with pliers) in the fire of a candle or a lighter.
3. Press the hot needle point into the Lexan where you have your Sharpie dots laid out. (Don't breath the fumes)
4. Check that the holes go all the way through the Lexan and aren't clogged by stray Polycarbonate. I checked the holes in my board with the leads from a resistor.
5. The wiring diagram is showed in the picture. It is very simple just 5 volts (represented by a battery) connected to a resistor and the resistor to the LED then the short leg of the LED (which also has a flat spot) is connected to ground. The resistor is a 470 ohm resistor so the bands are colored yellow, purple, brown, gold.
I have my ready Lexan "Circuit board" and I scored lines (like a checker board) onto it. Now I positioned the LED onto the Lexan so I could figure out where to put it. I heated the pin and pushed it through the board for my LED and resistor, making sure enough of the LED lead was left so I could properly position the LED so it points at the boards edge.
Step 4: Assemble the Circuit
2. When using polarity sensitive components such as LEDs make sure that you put them into the circuit properly the first time. Especially with Lexan circuit boards it is more difficult to desolder and fix any mistakes.
The weird contraption that my iron is sitting on is a solder iron "hot and ready" alarm that I made. When it's hot it cuts the solder wire and sets off an alarm. :)
Step 5: Power Up!
2. Connect the power. I loathe using batteries because I have so many little devices running around I use a lot of them. So now I just use an old cellphone charger to test my LED and low power circuits. It puts out 5 Volts and with a limiting resistor it is perfect.
Notice my power supply. I can never tell which wire is positive or negative so I just connect it both ways until 1 works. It shouldn't hurt the circuit, since this is a simple 2 component circuit.
Step 6: Admire
I added some black electrical tape to cut down on stray light from the LED. I wanted all the light to be focused on the edge of the Lexan so I covered it with tape. It also cuts down on the amount of light that escapes the board, since most of it reflects internally.
The last picture shows that the board remains very transparent even after components and scoring.
If you want anymore info about topics related to electronics you can ask me or Wikipedia has a great electronics library
Hope you enjoyed this and vote for me in any contest I may enter. Thanks!
Also, if you use this to make circuits or have criticism let me know in the comments.