Halloween Badges


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Software developer during day, hardware maker at night.

This is a follow up instruction for my LED jewelry. This time I bring you my Halloween collection - a bat, spider and ghost. Make yourself a unique Halloween badge that will glow in the dark. This time I made a video for you!

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Step 1: Watch the Video Tutorial!

Check out how the ghost is being designed and made. I tried to show all the steps as detailed as possible. The video should help you to see how to make these badges yourself without any trouble. Hope it will help.

Step 2: Gather All the Tools and Material

The key to success is proper material and tools. Here is what you gonna need.

Tools:

  • Narrow pliers
  • Round-nose pliers
  • Side cutters
  • Soldering station (idealy 900M-T-2C soldering tip)
  • Tweezers
  • Double sided tape
  • Piece of paper

Material:

  • 1mm/0.8mm straight brass rod
  • SMD 1206 LEDs
  • coin cell battery (CR2016, CR2025, CR2032, ..)
  • tin solder
  • soldering paste

Step 3: Start With Stencil

It's always the best to start with the paper template before actually start to waste wire. I prepared a special Halloween collection for you. You can create a bat, spider or adorable ghost. But I would love you to create your own shapes and share them with me!

Step 4: Place Everything on the Paper Stencil

Prepare yourself with the 2 copies of the paper stencil. Cover one of the stencils with double-sided tape. Use the second one to measure, cut and bend all the wire parts. Stick the wires onto the double-sided tape to match the paper template under it. Start from the outer shell, then place LEDs and finally the inner connections. Places the LEDs with the green arrow or T symbol on the back facing to you and pointing inside from the outer shell. It's wise to purchase more LEDs because these little bastards are easy to fly away.

Step 5: Solder Everything Together

Cover all the joints between the wires and LEDs with the solder paste and start slowly soldering the parts together. I am using 2mm flat-top soldering tip heated to 320°C and lead-based solder (Sn63Pb27). Soldering paste is required for the solder to stick onto the brass wires. Otherwise, it won't solder the wires together.

Make sure not to overheat the wire, the double-sided tape will start to lose its stickiness and parts will start to float around. Help yourself with the tweezers to hold the parts in the correct places.

Wanna blinky LEDs?

There is a special type of LED that contains a little microchip inside. This microchip allows for various effects from changing color to blinking. You can use these instead of standard LEDs to make a special effect!

Step 6: Create Battery Holder

Solder a wire on the back of the badge to create a pocket for a battery.

Step 7: Done

Now place a battery into the back of the badge and see how nicely it lit up! There are different types of coin batteries with different diameters and thickness. The only requirement is to use 3V battery. The battery depending on the size and number of LEDs used will last around 24h.

You might be wondering why there is no current limiting resistor. Won't the LED burn? My design uses an internal resistance of the battery. The battery itself won't allow such high current to burn the LEDs. Nasty trick.

Step 8: Make More and Share!

Make whatever shape you like, the only requirement is to create a proper circuit for the battery to lit up the LEDs.

I am Jiri Praus.

www.jiripraus.cz

Halloween Contest 2019

First Prize in the
Halloween Contest 2019

8 People Made This Project!

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26 Discussions

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NeilRGChrisR387

Answer 1 day ago

Hobby shops, also sold as brazing rod at hardware or welding supply stores

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desoldererChrisR387

Answer 26 days ago

I think electric copper wire should work too. Stretch it to get thinner wires and remove isolation easily.
Or wire that florists use to bind their flowers ...

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TimothyM116ChrisR387

Answer 5 weeks ago

I've found mine on ebay from the UK. Probably hobby shops or similar could have brass, but here is impossible to find one.

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AndyW63

Question 4 weeks ago

As several people have asked, where do you get the blinking LEDs? I've been looking all over because they would be perfect for a project I am wanting to make but I can't find them.

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desoldererAndyW63

Answer 26 days ago

I suppose you can use the ones you find on aliexpress when you search for "Flashing Blink LED Diode SMD". Just be aware that there are fast and slow flashing versions.
From what I have seen they all come in 0805 packages - so rather small.

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AndyW63desolderer

Reply 26 days ago

That's perfect! I assumed they would make blinkers for all the sizes but I guess they don't. Found tons of them on Amazon as well now.

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AndyW63chaotchaot

Reply 26 days ago

Someone else pointed out on my comment that you can find blinking in 0805 sized SMDs but not the 1206. I found them on both Amazon and Aliexpress at this point.

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ahombrados

5 weeks ago

Sorry if I'm being dense but how do you close the circuit for the spiders?

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AndyW63ahombrados

Reply 4 weeks ago

Chances are you would just run your other polarity wires back down the way they came along the back. That would be a lot of runs but you would get a super secure pocket to put the battery in.

They also may not have come out as well and that is why he didn't use any in photos.

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martindrew71

5 weeks ago

Nice project, I'll be doing this for next year. What software do you use to create the templates?

1 reply
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Perfect DIY

5 weeks ago

so cool!! great design!

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hugheswho

5 weeks ago

Clever idea, beautiful effect. I want to try this!

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M3G

5 weeks ago

These are fantastic, one of the best instructables I've seen in a while!

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獻章王1

5 weeks ago

Wah!! That's great~

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Build_it_Bob

5 weeks ago

Very nice! I remember looking at several of your other creations in the past.
You are VERY talented!
Bob D