LASER CUT LIGHT BOXES

Step 1:

Create a design for the front of your light box. Design it using either Corel or Illustrator. If this task seems to challenging or you don’t have enough time, simply find an image you enjoy on the web. Add the vector image to the center of the lid of your light box.

Adding the cut outs for hardware:

If you do not use the file (Attached file – 5x5x1.5 box.cdr) make sure you include the power adaptor jack cut out and power switch cut out.

Dimensions are as follows: 0.36” X 0.42” (power adaptor jack) and 0.41” X 0.23” (power switch). This is a great oppurtunity to have students measure the items and get accurate measurements.

Step 2: Cut out your light box

If you need help with the vector and/or raster settings, let an instructor know. Use the settings for your specific laser and material.

Step 3: Building the Box

Place sides together first. Use painters tape to hold the sides in place while gluing the box together.

Make sure you think about where you want your power adaptor jack and switch to be on the box. Hint: The keyhole on the back of the box is to hang the light box on the wall. Once you’ve found the perfect layout for you, go ahead and glue all the sides together.

DO NOT glue both of the covers… leave one side open in order to solder wires. 

Step 4: Installing the power adapter and switch

Install the power adaptor jack by inserting it from the inside of the box to the outside of the box. Glue it in place. Insert the power switch from the outside of the box to the inside. Ensure that the metal leads for the power adaptor jack are facing up. You will find that soldering wires to the leads are much easier in this position. 

Step 5: Soldering the wires

Cut wires to suit the layout of power adaptor jack, switch, and LED strip. Using wire strippers, pull off insulation from both sides of the wires. See the wiring diagram below when soldering. 

See layout of wires below see the pictures below for additional help. Remember when soldering to keep the tip clean and use flux often to clean the impurities out of the metal. This will help ensure your solders are adhering well.

Decide what color you want the LEDs to be. Notice the “G” “R” “B” written on the LED strip (see Figure 9). Make sure to solder your wire from the middle lead of the power switch to the copper lead of the color of your choosing. If you want to solder two colors together, to create a new color, grab a third piece of wire and solder to both colors of your choosing. The color combinations are as follows: Red and blue make purple, blue and green make teal, etc… 

Step 6: Check that wiring is correct

After soldering all wires, double check that everything is solder correctly by plugging in your power adapter and seeing if lights work.

Troubleshooting suggestions if lights don’t turn on: check to make sure power switch is in the correct “ON” position, check that all wires are fastened properly with solder and connections are good, all wires are correctly soldered (use wiring diagram as a guide), power adapter plug is plugged into working outlet. 

If everything is working correctly, pull off the back paper from the adhesive on LED strips and secure the LEDs around the inside of the box. Shut the front and/or back piece and glue shut (if desired).

Future Directions:

You can decorate the box using paint, markers, or vinyl stickers. Keep in mind that decorating the box before putting it together can be easier than decorating after it has already been assembled. You can also use hot glue to fill in the gaps. This can help diffuse the light and it gives it a nice glow.