I am one of the TAs for ES.100 – Introduction to Maker Skills. For the 2023 semester we got funding to run an LED Neon Sign making workshop. I decided to make an Appa sign to test out the process.
Designing the Sign
I started by finding a good image of Appa. I then used Adobe Illustrator to convert the image into a vector of just lines.
Then I offset all the paths to make the outline of the sign.
The LED strips I used came in increments of 1in so I made sure to design the sign to fit within those constraints.
Setting up the CAM
Once designed, I put the file into Fusion360 and setup the CAM. I used a 1/8" endmill to cut out the sign from a 1/4" sheet of acrylic.
Cutting the Sign
Then I cut out the sign on the Shopbot CNC router.
Wiring the Sign
This was the hardest part. I had to cut out the LED strips to fit into the different channels. Then I had solder them together and wrap the exposed wires in heat shrink to prevent shorts.
Since the copper pads on the LED strips were so small I had to used hot glue as a mechanical stress relief
Finally, I connected the sign to a 12V power supply and it lit up!