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Digital Stained Glass Windows

Illuminated, animated, digital stained glass windows��Steven Smethurst https://blog.abluestar.com/�Instagram, Twitter, Github: @Funvill

Version: 4

Last updated: November 21, 2022

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What are we doing today

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  • Learning the design rules, for how to make a digital stained glass window (30 mins)
  • Creating a vector image with LED pockets, walls, and LED holes (2-3 hours)
  • Cutting foam with a CNC router (1 hour)
  • Putting everything together (20 mins) �https://tinyurl.com/7rm9ru6v

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Parts list

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12MM WS2811 Square Pixel RGB LED Module 5V

Commonly called NeoPixels (~$50)�https://www.aliexpress.com/item/32803645847.html

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WEMOS WIFI ESP8266 Microprocessor

https://www.aliexpress.com/item/32529101036.html (~$11.00)

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Acrylic Lighting Panel + Extruded Polystyrene

Owens Corning Extruded Polystyrene ($28.98)�https://www.homedepot.ca/product/owens-corning-foamular-c-200-extruded-polystyrene-rigid-insulation-24-inch-x-96-inch-x-1-inch-butt-edge/1000155116

Optix Cracked Ice Clear Acrylic Lighting �Panel ($21.90) https://www.homedepot.ca/product/optix-cracked-ice-clear-acrylic-lighting-panel-23-75-inch-x-47-75-inch/1000143373

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11.5mm Drill-bit and Polyethylene Cutting Board

Polypropylene Cutting Board (Thin)�https://www.amazon.ca/Norpro-48-Flexible-Cutting-15-Inch/dp/B000S6OZQQ/

11.5mm Drilling Dia with 1/4 Inch Hex Shank 140mm Length (Fits LEDs)�https://www.amazon.ca/uxcell-Speed-11-5mm-Drilling-Length/dp/B09YTYKW9N

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Electronics wiring

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Example Designs

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Design your stained glass window

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Anatomy a digital stained glass window

  • A pocket (Red) is where the LED shines light though. �
  • A wall (Pink) is the part where light does not shine though. Walls are needed to separate the segments �
  • LED hole (Yellow) is where the LED will be placed within the segment.

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Design Rules

  1. Pockets need to be at least 3-4 cm wide. �
  2. Walls must all be connected and at least 1 cm wide�
  3. Walls need 2 connections to the outer walls. �
  4. One or more LEDs must be fully inside the pockets.

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Pockets need to be at least 3-4 cm wide.

This pocket is too small for the LED to fit into. I have found that a pocket about 2-3 cm or larger has the best result.

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Walls need to be connected to each other

All walls must all be connected to each other and connected to the outer walls.�It is suggested that you make at least two connections for each segment.

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LED Placement

Try to keep the LED in the center of the Pockets. For large pockets use multiple LEDs

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Good Design

  1. All pockets are 3-4 cm wide�
  2. All the walls are connected to each other�
  3. There are no “islands” of walls.�
  4. LEDs are in the center of the pockets.

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Make the design

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Download Vector files

Starting from an existing Vector file and altering it to match the design rules.

Places to get good vectors files

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Trace a image

Find an image online that you want to use. Then trace it in Inkscape.,

Use “Bezier curves and straight lines” tool to trace an image

Make the stroke 1 cm wide. This stroke width will make it easier to connect the walls together

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Cut the foam with a CNC Router

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Cut the foam using a CNC router

  1. ​

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Note

You can cut the foam with the Laser Cutter�Fast speed (100), Low power (20) �Watch for 🔥fires

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Drill the holes for the LEDS

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Mark where the LEDs should go and drill the holes

  1. Using the thin Polypropylene Cutting Board material, mark “X” where the LEDs should go. �
  2. Consider the length of the wire between LEDs. �
  3. Use a 11.5mm or 5/32” drill bit.

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Assemble the parts in the frame

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Insert the LEDs into the LED Panel

  • Insert the LEDs into the LED panel where the pockets overlap with a LED hole.��The LEDs should just snap in, if the are lose then use a bit of packing tape or hot glue to hold them in.

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Layer it all together and put it in the box

  1. LED Panel is on the bottom �
  2. Foam segments are in the middle �
  3. Light diffuser is on the top �
  4. Tape the edges of the panels together�
  5. Put everything into the box and connect to power.�

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You’re done!

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Where to go from here (Part 1)

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Where to go from here (Part 2)

Maker Labs has many other workshops and courses

Maker Labs https://www.makerlabs.com/ �Calendar https://www.makerlabs.com/calendar/

  • Maker Labs - 2D Vector Design 101 with Inkscape
  • Maker Labs - CNC Router 101
  • Maker Labs - Laser cutter 101