Remote-Controlled LED Desktop Lightbox (REVOLVE)

REVOLVE lightbox view 1 REVOLVE lightbox view 2 REVOLVE lightbox view 3 REVOLVE lightbox view 4

For my final project in Physical Computing of Spring 2025, I was tasked with either creating a new piece or refining a past project into a fully realized product. I chose to revisit my first project—an LED sign that spelled out "REVOLVE," the name of my record label. Rather than remake the sign entirely, I scaled it down to a desktop size that could be 3D printed in multiple parts and upgraded it to include a remote control sensor, eliminating the need to manually press the circuit board to turn it on.

First project reference

Getting Started

REVOLVE sign sketch
  • Set design constraints based on 3D printer max dimensions (about 250mm width, depth, and height)
  • Scaled down the original sign to fit within those limits
  • Added a hole at the bottom so the infrared sensor could receive signals from the remote
  • Made sure there was enough internal space to fit the circuit board and wiring
  • No breadboard was needed—circuit worked with just the IR sensor and LED connections

Planning The Build

Materials:

  • 3D printed material (PLA)
  • Hot glue
  • Black Duct Tape
  • 8 x 1 mm Magnets
  • Digital caliper
  • Circuit Playground Express board
  • Alligator to male wires
  • Aligator to female wires
  • 3X LED RGB Panels (8 x 8 Neopixels)
  • IR Remote
  • IR Remote Sensor

Steps:

  • Measured each RGB panel - 80mm x 3 = 240mm
  • Measured the circuit board - 50.7mm diameter
  • Measured the IR sensor - 12.56mm tall
  • Measured the sq ft of all wires together - 60mm x 65mm
Circuit board, IR remote, and sensor

3D Modeling

3D model view 1
3D model view 2 3D model view 3
  • Used Onshape to plan the build based on measured constraints
  • Designed a front frame inspired by the original REVOLVE sign
  • Created a clear frame for the LED light to shine through
  • Added spacers to support and align internal components
  • Modeled the back panel to hold all electronics securely
  • Left a gap at the bottom for wire routing
  • Designed a bottom chamber to house the circuit board and sensor
  • Included a small hole for the sensor and another for the power cord exit
  • Used the chamfer tool to make the "underground" cuts and grooves look more chipped and cracked

Printing Process

  • Imported five separate pieces into Bambu Studio for printing: front frame, clear LED cover, back holder, bottom chamber, and chamber door
  • Separated the parts to allow for proper assembly after printing
  • Added supports to the main compartment and spliced the file
  • Exported the spliced file and began the printing process

Wiring / Coding the LED Panel

IR Remote in Action

Code

Python Code

  • Used Mu Editor with a Python script to read IR remote pulse data via the terminal
  • Collected pulse data for buttons 1–6 to assign six different colors to the panel
  • Captured pulse data for the power button to toggle the device on and off
  • Planned to include more features like LED chase effects, brightness control, and extra colors
  • Limited RAM on the board (due to 192 NeoPixels) restricted how much functionality could be added

Inputs / Outputs:

Inputs Outputs
Power ButtonTurns device on or off
Button 1Makes neopixels purple
Button 2Yellow
Button 3Red
Button 4Green
Button 5Blue
Button 6White

Assembly

  • Pieced together all three NeoPixel LED panels and taped down the wires to save space
  • Attached the LED panels to the clear PLA frame and began visualizing the full assembly
  • Hot glued the REVOLVE letters to the center of the clear frame
  • Fit the clear frame snugly into the back holder
  • Placed the main front frame over everything and secured it with black duct tape to hold it precisely and cover separation lines
  • Fed the IR sensor into the bottom chamber and secured it with duct tape in front of the sensor hole
  • Inserted the rest of the circuitry, making sure everything fit neatly inside
  • Added 8 magnets to the bottom chamber and 8 to the top frame so the pieces could clip together securely but still be easily disassembled
  • Attached a side door to cover the bottom chamber opening, using duct tape while leaving space for the power cord to feed out
Assembly view 1 Assembly view 2
Side view 1 Side view 2 Side view 3

Finished Remote-Controlled Desktop Lightbox

Purple Yellow Red Green Blue White

Reflection

What Worked Well:

  • The prints came out clean with minimal warping—each piece fit as intended
  • The IR sensor functions reliably from 5–10 feet away
  • The LEDs shine clearly through the clear PLA and create a strong visual effect
  • All hardware fit perfectly in the bottom chamber without feeling cramped
  • The magnets are both functional and visually clean, helping the device stay secure
  • The final design matched the original vision and looks aesthetic on any desk

Challenges & Limitations:

  • Limited RAM on the circuit board restricted the number of features that could be added via remote control
  • Originally aimed to use 9 remote buttons for color selection, brightness control, and NeoPixel animations
  • The 192 NeoPixels and IR pulse data consumed most of the circuit board's RAM
  • Adding more functionality caused the board to overload and crash
  • Settled on 6 color options with on/off capability, which was still satisfying

Takeaways:

  • Future iterations could use a board with more RAM to support expanded features like animations and brightness control via remote
  • The goal was to revise my original REVOLVE LED wall sign (approx. 19"×12") made from cardboard and Cricut-cut letters
  • This version was scaled down, 3D printed, and fully enclosed to resemble a polished, functional product
  • The final piece is durable, cleanly assembled, and visually high-quality
  • Thorough planning led to a result that exceeded expectations
  • Future versions could support more remote functions with additional inputs/outputs
  • Despite hardware limitations, this was a successful and complete first prototype that met all core design goals