Overview

We will be using custom PCB connectors.  The LED side is matched to the LED strip, so the strip can be conveniently soldered to the PCB connector without wires. This will also keep the “no visible LED light zone” to a minimal. The design is shared on OSHPark. (Complete assembled sets may be available here at a later time)

1m 144 LED/m LED strips usually come as 2 half meter strips with a solder joint. For best results select strips where this joint is minimal.

• 2x WS2812B LED Strips 144LED/m Density
• Clear Heat Shrink Tube 12mm Diameter
• Polycarbonate Tube Thin Walled (For Blade)
• Polycarbonate Tube Thick Wall  (For Plug)
• Blade Tip
• LED Diffuser Tube Thick Walled
• LED Diffuser Tube Thin Walled
• LED Strip Foam Tube
• 22 AWG Solid Wire
• Blade Custom PCB Connector
• Hilt Custom PCB Connector
• Plug Custom PCB Connector
• Spring Loaded Contact Pins
• 3D Printed Parts

Blade

Start by unsoldering any lead wires that come with the LED strip

By soldering the positive wire to the opposite end of the LED strip, current will be distributed evenly. This will remove any “brown out” effect, where the first LEDs in the chain are brighter than the last LEDs. I find it best to heat the pad from the front and poke through from the back of the pad.

Peel back the adhesive strip and run the positive wire down the adhesive back. Try to place the wire slightly to the left of the center. After repeating this for the other strip, match them up back to back, and stick them together.

Clip off the positive pad on the LED strip. The lead wire will be used to connect to the PCB connector. Also trim the excess strip, so that the pads touch the end.

Pretin both the LED strip pads and the connector.

Use helping hands to hold the PCB connector in place. Briefly poking the 2 pretined pad should join them.

Heat shrink tubing will help protect and retain the 2 LED strips. Assembly the connector mate, foam, LED diffuser and polycarbonate tube.

The length of the polycarbonate tube, matching the selected blade tip and connector mate, should be:
LED strip length + .165 inches

The LED diffuser tube and foam tube should be:
Polycarbonate tube – .4 inches

Blade Plug

Start by cutting the LED strips to size. 5 LEDs length is a good fit for a 1.75 in plug.

Use the 3D printed piece the mount the LED strip.

Again, poking both pretined pads will join them.

If you do not have access to a lathe or mill to trim down the black cap piece, a 3D printed cap can be used instead. For a 3D printed plug cap, some acetone can be brushed on to smooth the surface, and in addition softening the hole to allow self tapping for the center brass pin. The 3D printed cap can be press fit the same way.

Continue assembly with the connector mate, diffuser tube, and polycarbonate tube.

Hilt Side Connector

Use either helpings or a PCB mount to hold the PCB, and drop in the pins. Each pin is rated for 2A so 4 pins for each positive and ground side would be preferred over 2 for each side.

Press firmly on the of the pin as you solder them, so excess solder does not flow through the hole.

Done!