SEAN JOSEPH ANDREWS


Selected Works
NAALIYAH STUDIOS Shopify Web 
PHYSICAL COMPUTING Project
UI/UX Applications
UNDERLINE COOLING Project
PLANT HEALTH MONITOR Project
HYDE CLOSET Case Study 
UNITY Game Design  
MISC.


RESUME
ABOUT ME
COURSEWORK




©2024 Sean Andrews


Revolve Underground LED Sign





For my first project in Physical Computing of Spring 2025, the task was to create a diorama that expresses something personal about myself, using a combination of paper, a vinyl cutter, and programmable electronics. I drew inspiration from a personal venture that began in January 2025 when a few friends and I started a record label in San Diego and branded it as “Revolve Records”. Our goal was to boost the deep/tech house music scene and discover creative methods to promote and brand our label. Creating a dynamic, LED-lit sign seemed like the perfect blend of technology and expression to spotlight Revolve.

Getting Started


The initial step was to lay out all my creative thoughts and conceptualize the design visually. This process began with jotting down every idea that came to mind and then translating these concepts into basic sketches. These sketches served as the foundational blueprints that shaped the project's direction.

The design needed to be unique, incorporating multiple layers to add depth. I imagined utilizing sheets of black paper, each featuring crater-like cutouts with spaces between them, which added layers of texture to the design. Central to the design was a panel of RGB LEDs, which would backlight the 'Revolve' letters to create a silhouette effect, mimicking the pulse of house music. Allow me to guide you through my thought process and how I brought everything together.



Procreate Drawings - 5 Total Layers
  • Used Procreate on iPad to design the sign's front with a chipped/broken asphalt motif
  • Symbolizes the breakthrough of the underground music scene
  • Initial designs set aesthetic and functional parameters for the project
  • Converted design layers and logo into PNG files for Cricut Design Space


Test Print




  • Shrunk cutout PNGs in Cricut Design Space for better margins of 1.5 - 2 inches between layers
  • Conducted test print with 11 x 17 inch black cardstock and white printer paper to assess Cricut Maker 3 vinyl cutter use
  • Test print determined optimal sizing and placement of cutouts to match design vision and equipment capabilities
  • Checked material sufficiency for holding the design together
  • Satisfied with test results, proceeded to refine and perfect the design


The Vision
Layer with styrafoam


  • Adjusted sizing and placement of crater cutouts and refined 'REVOLVE' logo dimensions after test print feedback
  • Enlarged the smallest opening in the cutout, especially the 5th layer, for better LED panel illumination
  • Reconfigured PNG cutout sizes to fit LED panel and securely encase 'REVOLVE' letters
  • Enlarged the logo, particularly the globe symbol, to enhance the cutting process and scaled up the entire design for uniformity
  • Final mockup measured about 4.3 inches x 14 inches, perfectly centered on the 11 inch x 17 inch black cardstock paper


Final Print 


With these adjustments, I finalized the layout and was ready to move forward. This preparation set the stage for crafting the final version of the project, requiring careful planning and organization of the materials needed for completion.


Materials:

  • 11 inch x 17 inch Black Cardstock (80 lbs)
  • White Cardstock (80 lbs)
  • Styrafoam for spacers
  • Black Spray Paint + Primer
  • Velcro Strips

  • Packaging Tape
  • Gorilla Glue
  • Elmers Glue Stick
  • Scissors
  • Exacto Knife
  • Tape Measure + Straight Edge

  • Adafruit Circuit Playground Express Board
  • 3 connective wires (GND, Power, and A2)
  • USB cord
  • RGB LED Panel (WS2812B, 256 neopixels)
Cricut Design Space Software - Exact Print Details

First Step:

  • Completed final prints with vinyl cutter, ensuring precise centering on 11 x 17 inch black cardstock
  • Successful print of five paper sheets and cleaner 'REVOLVE' letters due to size adjustments
  • Measured front frame; total thickness of stacked frames was 1.25 inches
  • Recorded dimensions critical for designing supportive frame
  • Careful planning and execution vital for assembling final project version

New Logo Cutout Difference

11 inches tall

17 inches wide
1.25 inches deep



Coding the RGB Panel


  • Finalized main design and tested LED panel illumination through cutouts
  • Programmed LED panel for a dynamic "chase" effect, mimicking movement
  • Adapted NeoPixel sequence code to match vision, setting specific colors and speeds
  • Programmed LEDs to highlight 'REVOLVE' letters and enhance design aesthetic
  • Configured sign with 5 movement patterns and colors, alternating every 10 seconds
  • Added input-output code for simple on-off switch functionality on the circuit board

LED Panel --> Adafruit:
5V --> VOUT
GND --> GND
DIN --> A2

Mu Editor Code - 5 Different Light Modes After 10 Seconds Each - On-Off Switch 


Creating The Frame


  • Cutouts, logo, and LED programming completed, started building the cardboard frame for stability and ease of cutting
  • Designed a simple shell frame with a front and back cover to secure all pieces in place
  • Measured total dimensions for stacked cutouts at 17 x 11 x 12.25 inches and drafted initial frame designs
  • Sketched blueprint focusing on frame dimensions and connection points
  • Adjusted frame dimensions for better fit and added support: increased length to 17.25 inches for stability
  • Extended front and back frame by a half-inch for assembly tolerance
  • Incorporated an opening in the back frame for LED panel visibility and a 1.25-inch margin in the front frame





  • Drew up frame design and visited Home Depot for supplies
  • Purchased cardboard, an exacto knife, and spray paint for finishing
  • Transferred blueprint from iPad to cardboard at home
  • Began cutting out frame pieces





Assembly


All Papers Stacked and Perfectly Aligned

  • Began careful gluing phase, crucial to avoid redoing printing and cutting
  • Used glue stick for placing logo cutouts on white paper
  • Checked fit by aligning cardboard perimeter frame around the cardstock
  • Temporarily taped cardboard pieces to maintain alignment during gluing
  • Inserted eight 1 inch by 1 inch styrofoam pieces, 4 mm thick, between layers for even spacing and added depth



Putting Pressure Over the Cardboard While the Glue Dries
Feet Stands - 3 inches x 0.5 inches
Packaging Tape around the Edges to Secure the Frame



  • Spray painted all pieces then began assembling cardboard frames
  • Applied superglue along edges for a strong bond and added stiffness
  • Wrapped edges with packaging tape for extra support and a cleaner look
  • Reinforcement gave the frame a more finished appearance




  • Connected LED board using alligator clips to appropriate pins
  • Secured wiring on the back with tape and velcro for organization and easy removal
  • Attached little feet cutouts to the frame's bottom, completing assembly
  • Designed the piece to be lightweight for wall hanging, enhancing display flexibility


Finished Sign with On and Off Modes