3D Printed Text Sign designed in Fusion360 and running WLED

Introduction

In this article, I will share my experience of creating a 3D logo using Fusion 360, alongside integrating LED lights with WLED for a stunning final result. This project involved several steps from designing the text sign, printing the components, and finally, assembling everything together with LED strips. Below is a detailed breakdown of each step.

Designing in Fusion 360

1. Text Creation:

   • I initiated the process in Fusion 360 by creating text for my logo, specifically the letters "L", "J", and "M". Knowing I wanted a size of around 70 mm, I set the appropriate dimensions.

2. Exploding the Text:

   • After entering the text, I had to "explode" it, which allowed me to manipulate each letter individually. Following this, I removed the constraints to enable easier editing.

3. Creating Offsets:

   • To prepare for the base of the logo, I created an offset layer to ensure the letters would have a consistent overlap. This step is crucial as it would support the caps I planned to add later.

4. Extruding the Base:

   • I selected the letter "L" and performed an extrusion of about 2 mm to create a base that I could use to assemble the letters later.

5. Naming Components:

   • Each part of my design was explicitly named (e.g., 'Base L', 'Base J', etc.), which simplified the export process later on.

6. Extruding External and Internal Features:

   • Next, I selected the outer area of each text object and extruded it to around 20 mm in height. I also selected the inner lip for extrusion, setting it to 10 mm, which created a fitting surface for the caps.

7. Creating Additional Features:

   • I incorporated holes and other features by manipulating the letters through various extrusion processes, and created the caps that would sit atop each letter.

8. Exporting the Design:

   • The completed designs were exported as STL files, ready for slicing. I used Cura as my slicer software to prepare the model for 3D printing.

3D Printing and Assembly

The next day, I focused on preparing the necessary electronics. After a good amount of soldering, I carefully installed the LED strips.

1. Preparing LED Strips:

   • I began by soldering the LED components, ensuring everything was neatly connected. The setup involved connecting to a D1 Mini running a WLED program.

2. Testing the LEDs:

   • Once the software was loaded onto the mini processor, I checked if the LED lights powered on successfully, signaling that everything was functioning as it should.

3. Final Assembly:

   • After connecting to the WLED access point, I configured the Wi-Fi settings, allowing for remote control of the lights. The tricky part was peeling off the adhesive backing of the LEDs and sticking them securely on the inside of the printed letters.

4. Enclosure and Wiring:

   • I printed a small enclosure unit to house and secure the wiring. Some adjustments were made for a proper fit since tolerances didn't align perfectly.

5. Final Result:

   • The project culminated with all wires soldered, LEDs set, and everything secured together successfully. Using the WLED app on my phone, I could control the lights, and the final output was a beautiful illuminated text sign that stands out.

Keywords

3D printing, Fusion 360, LED strips, WLED, text sign, STL export, Cura slicer, design, electronics assembly.

FAQ

Q: What software did you use for designing the 3D logo?
A: I used Fusion 360 for designing the text sign.

Q: How did you prepare the logo for 3D printing?
A: The final designs were exported as STL files and then sliced using Cura.

Q: What kind of LED control did you implement?
A: I implemented the WLED software on a D1 Mini to control the LED strips.

Q: What was the size of the text logo?
A: The letters were set to approximately 70 mm in size.

Q: Were any adjustments required during assembly?
A: Yes, I had to make some adjustments to the enclosure due to unexpected tolerances.