Introduction: DIY PaperCircuitSheet(PCS)-Rocket With Copper Band & LED

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About: My name is Sabine. I'm a hobbyist with a variety of interests, including 3D printing, tinkering, music, stories etc.
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Paper is the theme and I've had something spacy, copperish in my mind which includes illumination and most of all a lot of fun making it.

And here it is: copper one - the PCS-Rocket (PaperCircuitSheet-Rocket)

Step 1: ​The Gear I've Used

  • Paper
  • Acrylic Paints (black, gold, dark brown)
  • Palette Knife/Brush
  • Sissors/Cutter
  • Glue/Tape (any kind of)
  • Copper Band (self-adhesive) and Copper Wire
  • LEDs (from flashlights)
  • Battery holder and Batteries (from flashlights)
  • Push Button Switch (from flashlights)
  • Wire/Cable/Strand
  • Lever Nuts
  • Wire Stripper
  • Nippers
  • 3D Printer
  • PLA Filament (white)
  • Software: Tinkercad, ideaMaker, paint.net

Please take all necessary safety precautions while working with heat, sharp objects, electricity, vapors or resulting gases, bright light and whatever could endanger your health.

Step 2: The Prototypes

I made two prototypes to figure out the final design and where to add the components. I designed a 2D model in Tinkercad and added the wiring in paint.net.

Step 3: The Battery Box and the Nose

Battery Box: I shaped a paper cylinder, taped the name tag on and added the cover lids and battery holder.

Nose: I shaped a paper cone from a semicircle and taped it on the PCS. The copper band is just decor.

Step 4: The LEDs

To make it as simple as possible I took two cheap flashlights* apart and pulled out the needed components:

  • 2 LED boards
  • 1 battery holder
  • 1 push button switch

I also cut out pieces of LED stripes in the preferred length as well.

All LEDs set to run at 4.5 V and run off three AA or AAA batteries.

My flashlights came with an AAA battery holder so I used this one.

* Using the components from flashlights was inspired by Punished Props Academy - Easy LED Lights for Cosplay!
I usually don't like to destroy working things but in this case I went for the simplest and cheapest way.

Step 5: ​The Paper Moon

I spontaneously decided to create a very simple paper moon. The USB-LEDs are powered autonomously via a power bank.

Step 6: The PaperCircuitSheet

2.1 The Rocketshape

Well, I'm not very good when it comes to drawing, so after I found a picture of the Ariane 5 Rocket on the internet I decided to go for this shape.

I streched out the picture because I needed more room for the components in the center of the rocket's body.

I transferd the shape to the papersheet using my black acrylic paint and palette knifes.

2.2 The Copper Band

I guess, copper band is often used in railway model making to tap the electricity at any point you like. And that's excactly what I was looking for.

I cut the pieces in the length I've measured on my prototype-models and because it is self-adhesive I just taped it on the papersheet in the places I picked out.

2.3 The Wiring

I took a red wire for the positive pole and a green wire for the negative pole for most parts of the build and started to find out which connection would make the LEDs shine.
I forwent soldering and taped, glued, pinned, tacked and crimped it. For some parts of the cable links I used lever nuts - this made it very easy. BUT to be completely blunt: Not soldering isn't the most reliable solution.

2.4 The 3D Printing

I 3D printed the cover lids for the battery holder and the name tag in white PLA filament; dry brushed with the acrylic paint. Because I had no copper paint in store I mixed gold and a little bit of dark brown.

Step 7: ​Thank You …

... for reading, watching and paying attention. I have summarized all the pictures in a video.

I hope you will find this any kind of inspiring. It was fun to make and always is a learning experience. I think, this could be a nice project to do with kids. Maybe in shape of a car or a building - like a castle.

You may have noticed that my PCS-Rocket wasn't built for enternity. As I mentioned before if you want it more solid I recommend to solder or use (luster/terminal) clamps or whatever makes it sturdy.

Please let me know if you've made one by yourself.

Hopefully Auf Wiedersehen in one of my next instructables.