Introduction: 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

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

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

Step 4: 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

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

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

Step 7: 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

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

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

Step 10: Drilling Holes Part 2

I used a 0.035" drill bit for the holes.

Step 11: 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

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

Step 13: Soldering

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

Step 14: 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

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.

Step 16: 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

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

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