RGB Mask PCB Edition
Introduction: RGB Mask PCB Edition
Hey guys what's up
So this is my RGB Mask project that is made from soldering 5 PCBs together, This RGB mask has 52 WS2812B LEDs and they are controlled by an ESP8266 microcontroller module.
BUT Does this work as an actual face mask?
No, not really but we can wear a normal mask beneath this RGB mask and stay safe.
I first made a cardboard mask and then use its measurements for making a PCB design which has solderings pads on edge of PCB. by putting PCBs together in the right order and soldering them at a certain angle, we can combine two or more 2 PCBs to create a PCB structure or shape. with this method, we can make anything with PCBs even a PCB Hat or Iron man's Helmet, we just need to follow the basic geometry and that's pretty much it.
I previously made a Project with the same Method - https://www.instructables.com/RGB-Glasses/
Supplies
these are the things that I used in this project!
* Custom PCBs (which were provided by JLCPCB)
* ESP12F
* 10k resistors
* WS2812b LEDs
* ams1117 voltage regulator
* 10uf capacitor
* 1uf capacitor
* 100nf capacitor
* SMT reflow hotplate
* solder paste
* patience
Step 1: Schematic and PCB Designing
I First Prepared a Cardboard mask with a basic mask shape I made, by taking this shape as my main reference, I prepared a schematic around it.
My ultimate goal was to use FR4 PCBs instead of Flexible PCBs, FR4 PCBs cannot bend and they are hard which is not ideal for such projects at all but Flexible PCBs can be folded into a mask shape without any problem, so why didn't I use Flexible PCBs?
The reason is pretty simple, Flexible PCBs are too fragile and they cannot withstand my current project which requires a hard surface.
Schematic of This project seems complicated at first but it's basically 52 WS2812B LEDs connected with an ESP12F Minimal setup and have an AMS1117 Voltage regulator for stepping down Voltage from Battery and USB Side.
Now, This Project requires a total of 5 PCBs, and making them all separately was not a hard thing but ordering 5 PCBs would cost more so I prepared this Project's PCB in such a way that a Huge PCB can be broken down into 5 Different PCB shapes.
To Accomplish This Task, I prepared the Schematic in this way-
* Each section/PCB shape contains the components (RGB LEDs, Capacitors, etc), at the edge of each PCB section, there are three connector Pads for VCC, Din, and GND.
* Two PCBs can be Joined by soldering connector Pads of Two PCBs together.
I Joined all PCBs together with this method along with its electronics wiring and connections.
after finalizing the PCB and checking it thoroughly, I sent the Gerber data to JLPCB for samples and received them after few weeks.
PCBs that I received was great as expected! check them out if you need great PCB service at a low cost.
Step 2: Why ESP12F?
So why did I used ESP12F in this Project?
The reason is the Connectivity issue with other MCUs. If I used an Atmega CHIP or other small MCUs like Attiny for example, I needed to add an extra BT, NRF, or WIFI module for communicating with the mask and toggle LEDs which would increase the number of components used in this mask.
I wanted to control this mask with a webserver so for this task an ESP8266 would be perfect here but I don't want to use Nodemcu because of its size, so I use ESP12F minimal setup (schematic is provided).
It's small and has all the features which are required for this project.
Step 3: PCB Assembly and Reflow Process
I followed the following steps for assembling each PCB-
* I cut down the single Huge PCB into 5 different PCB shapes with a cutter. 982