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New Workshop Setup - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://www.solcrusher.com/blog/2019/4/3/sol-burst monthly 0.5 2023-09-06 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964718651-DGQT08WC2IHJOXWJ5Y25/IMG_0410.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964932423-WMYR5H5C72T8LQE5VG1X/IMG_0411.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964932216-QZKX9AV3Z0Y76R9N1XOC/IMG_0412.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964934961-5IFITNIWTBQ72W27UOGB/IMG_0459.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964936537-QD9FKUU3LJGCMIGMLYO1/IMG_0470.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964937598-8GF1KH0WMCTFR9X7UG5H/IMG_0472.jpeg Blog - 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SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964970946-0W1H2YM822WWOK8JSFT7/IMG_0570.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964975172-BU4597W0IM41RE8GUL2K/IMG_0572.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964974018-J9MJEPTXKLROTWGNWTYO/IMG_0583.JPG Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964976063-UNYTR93LFC308K0UADGM/IMG_0586.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964977559-NFA20Z13KLN5RPF84TMB/IMG_0588.jpeg Blog - SOL BURST https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1693964718922-W0M2NIM6VCDYR58SW3LE/IMG_1018.jpeg Blog - SOL BURST - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://www.solcrusher.com/blog/2018/7/30/sol-crusher-v2 monthly 0.5 2023-10-11 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533518380389-E5QOMSXF7KLVT2UHBLNT/image-asset.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533516127651-IN3GMJQQZOPOUPCWLDPE/Screenshot+2018-08-05+17.41.23.png Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533496707318-SBBXFPWU3U9NR4W2W04Z/AAB.png Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533509316278-7UUQHE153QYQIL04DXOI/Totem+v13.png Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533518685779-XA2EQZBGD3OZYZ82W7LS/IMG_1576.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533509364498-CWQHIQQ7ONXH3Z0JESVY/GeoSphere+v26.png Blog - SOL CRUSHER V2.0 At some point I want to add some plastic panels to the inside to catch the light of the internal LEDs but I haven't gotten around to this yet. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533438399694-DLMOJTFAI9VLZOFLMIQG/IMG_1360.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533513554991-Y1SMZ30ZTYSF47Y5QSWT/IMG_1561.jpg Blog - SOL CRUSHER V2.0 Putting it all together and things are looking great. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533513920365-F34VRCQ39TQQ6VFHKEAV/IMG_1566.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533438529822-X6YGQQ1B5BZ199DDCOY8/image-asset.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514216717-3XCEKJ2MJIDT5ATTF99G/IMG_0918.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533510995593-H5A6RPSWJ8DMOF1QOGRS/image-asset.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533438723044-5Y4TI6T5IB0Z52ZIQACL/IMG_1424.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533497397516-RW9ZV5M8Q7ZV2AM3J0C6/DIY_Geodesic_Dome_Greenhouse9.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533507864134-4WYS59FDJKT918D8ZVUX/image-asset.png Blog - SOL CRUSHER V2.0 This is a hexagon panel built from CCB boards. It's put together in the same way as the pentagons. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533510355562-1BRKZUAOLTDH9GDU7UBM/IMG_1416.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533508052365-CUXMZMA3935C8DDH394U/Hub+3.png Blog - SOL CRUSHER V2.0 The cutouts were then mirrored and rotated copied to complete the lightened structure. The little slots were to pass wires through since I originally was planning on using carbon fiber rods and passing the wires through the center. These proved to be too weak and I switched to wooden dowels so the slots were not used. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533511029612-HQSRRYQTGKILYVGV10QF/image-asset.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533496918954-I25CSLRCTTLZPVFD2EB5/Screenshot+2018-08-04+21.53.01.png Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533510789593-B0ZUD156WFT9RDNPMAD1/IMG_1543.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533511172573-GDG3JQYJLJ565X28PCQ9/IMG_1551.jpg Blog - SOL CRUSHER V2.0 Since the hub was such a complicated part, I didn't really feel comfortable printing it myself. So I uploaded the design to Shapeways and had it printed in their "Strong and Flexible" materal. While expensive, the print came out absolutely flawless https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533507481321-ZC9HL689JARB76M59XYN/Pent+v21.png Blog - SOL CRUSHER V2.0 This is how the boards and support come together to form a pentagon panel. Each one of these will be connected to it's own data line from the Teensy microcontroller. This means a single LED failure will at most only remove a single panel of LEDs. In practice I've only seen at most 3 or 4 LEDs near the end of the chain glitch out, so even when a couple LEDs die, the animations still look great! https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533508367642-IR0555HYI4D9XVQVSZHC/image-asset.png Blog - SOL CRUSHER V2.0 Then I cut the sphere in half and added some points where it could connect back together with some set screws. This allows the top and bottom half of the totem to be separated to get me access to the insides. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533515267046-Y0EPTCHUXVRDH6BUBU5O/IMG_1501.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514444264-RFV3VWGKNKR21HB7M3B7/IMG_1502.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514444180-PE1YCYUQPRK1U4TLR0DF/IMG_1503.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514464308-OQYQHAXOMGLGTU948G9W/IMG_1504.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514454519-2980KIXMZMP65LZHQ84T/IMG_1507.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514463802-IZ4G2XLAAYHAA5547TMV/IMG_1508.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514472367-5R1EMGTTLBVH67ESN99T/IMG_1510.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514471943-0823PUS7X5WIIAT2FV0F/IMG_1512.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514498400-MJ9PI86CYUJSI9J9IALL/IMG_2037.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514481011-YOF064BVNY0TP3TFJ6HI/IMG_1517.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514490230-BVC3SVISEPBZR55Y8Z5F/IMG_1518.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514492975-LGXT07IDFEEQVWL6BQ2T/IMG_1523.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533438433903-8QAKTCXVPTLBOF7PXZGX/image-asset.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533510504991-UP7TPQAG3YE4VBGHFYFU/Screenshot+2018-08-05+16.07.50.png Blog - SOL CRUSHER V2.0 I decided to use these tiny little JST SR connectors to get the power and data to each panel. With pins only 1mm apart, they were a total pain to solder, but they ended up working great and fit nicely on the back of the panels. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533508295599-GAC9JUWVE8V8SY0KT0LU/Hub+5.png Blog - SOL CRUSHER V2.0 To connect to the pole (same pool skimmer pole as last time) I extruded a cylinder out the bottom and blended it into the hub. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533438450942-7WTHCWXIER1M7PSHYFW0/IMG_1370.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533508232269-4SPJ0P0ZKQMC8TV0YMC3/image-asset.png Blog - SOL CRUSHER V2.0 I also added some small cutouts in each of the beams to zip tie the wires in place and keep things tidy. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533514169575-8MOXFRP0IO78BKQ16P1N/IMG_0917.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533510190151-C02HNUN1T23K45QYL80X/IMG_0916.jpg Blog - SOL CRUSHER V2.0 I could use the 3D printed supports to hold the circuit boards at the correct angles while soldering them together. This was much simpler than the jigs I made the last time for a similar purpose. You can see scorch marks from where the soldering iron was getting close to the plastic. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533512917336-5STI2ELR41CZDWPTKKXR/IMG_1552.jpg Blog - SOL CRUSHER V2.0 Test fitting the bottom panel and pole. Everything is fitting together nicely. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533504148808-0J55XEKNDPO6V97DAD19/Hub+9.png Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533507987934-HNBN8QRF9F6FVX6LMT6M/Hub+2.png Blog - SOL CRUSHER V2.0 I then made several cutouts to reduce the amount of material used and lighten the ball. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533438667178-3QXBTZSUB01RJVTT97T9/IMG_1407.jpg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533508329573-WFRD39NM2VVDENJCZYCJ/Hub+6.png Blog - SOL CRUSHER V2.0 I then added some mounting locations for the circuit board. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533507950872-CPLS4O8TDEV2ZFBUEJ14/image-asset.png Blog - SOL CRUSHER V2.0 The design of the center hub to connect the panels to and house the power converters was tricky and really stressed the limits of Fusion 360. I started with a hollow sphere with a hole for each of the support rods. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533509198802-LFWJEHU7ECEMI54IMH10/Hub+8.png Blog - SOL CRUSHER V2.0 The bottom then needed to be extended to provide a mounting location for the bottom pentagon. The two little nubs are for set screws that will lock the totem to the pole. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533507583628-6KOPDHXVX8ZE5SP78A54/Support.png Blog - SOL CRUSHER V2.0 This is the support structure for the pentagon panels. I made these a lot smaller this time, only holding on to the top part of each panel. This time around I used Fusion 360 to model things. This software is free to use for makers and small businesses. While it has a bit of a different workflow than other parametric CAD software, once I figured it out it proved to be a solid solution. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533496752304-9WSLUHUD9TFD5UMXT2K8/AAB+Back.png Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048460392-75HDHEJWSYPXTFARCNJ6/IMG_1398.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048457538-TF56P94ZJOME3CRSWL6I/IMG_1333.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048462857-TH5FFRBMV8FFZC4ZJVKZ/IMG_1401.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048461925-JD6CWZV3SMOSBJ2BWSMA/IMG_1400.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048461368-5PCO9D57K3N5F656ZNQ6/IMG_1399.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048459700-SK7YYUMHRK3ANE9HWGA4/IMG_1349.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048449119-YUPQGA13DFJZMDOVOY3X/IMG_0012.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048449710-U95E54AVSW3OW6TCN72R/IMG_0013.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048450570-0MXHG061TWP67KIOT5GZ/IMG_0191.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048452958-DO1PL2YDTSSCT61ZO0TJ/IMG_0984.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048452045-2UI1JIRB5P3143QJ5K83/IMG_1085.JPG Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048455781-218F53W9OE4DA81HC4FL/IMG_1117.jpeg Blog - SOL CRUSHER V2.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1697048457142-VT3PVXCLNC6XYBNOXFJK/IMG_1312.JPG Blog - SOL CRUSHER V2.0 https://www.solcrusher.com/blog/2016/6/6/sol-crusher-v1-build-log monthly 0.5 2023-09-06 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010661110-VQ6BTUJSWLL7MRJPIUZP/SC1_19.jpg Blog - SOL CRUSHER V1.0 I 3D printed an enclosure to hold the low voltage cutoff board and added a power status LED. I can also hold one additional fuse. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533013390971-CZXGRL9IDMAYSQBVVXV4/SC1_36.jpg Blog - SOL CRUSHER V1.0 First two panels on the totem! https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009775530-Q7YO3671IL8NSP1TNC6V/SC1_14.jpg Blog - SOL CRUSHER V1.0 The 5V 30A voltage regulator needed some connectors. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533013525329-OOZZOIC80CAHQ4CFQVO4/SC1_40.jpg Blog - SOL CRUSHER V1.0 And the bottom half is done! https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533013357419-AK1L5X44AGX3CS2YLYJW/SC1_35.jpg Blog - SOL CRUSHER V1.0 Here is the center hub. The fiberglass rods will fit over the nubs and the top and bottom halves can separate. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533012197931-HYTN976WTYBCBP1YUKVS/SC1_27.jpg Blog - SOL CRUSHER V1.0 And the quality turned out great! https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533012998702-8ETBKQFUC19T0WHVOZVR/SC1_32.jpg Blog - SOL CRUSHER V1.0 With the first panel together I can start to see how it's gonna look. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009741420-1Z7TII1XT3W5AZBKNEA4/SC1_13.jpg Blog - SOL CRUSHER V1.0 Luckily it was easy to solder on a fuse holder. You really don't want LiPo batteries to short. Especially the size I'm using. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010622749-E5G0JOWW8GJQC5K2D4N3/SC1_18.jpg Blog - SOL CRUSHER V1.0 Here's the power system all wired up and showing a steady 5V! Note that I got a LiPo safe so that should something go terribly wrong, the LiPo fire will be somewhat contained... https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010763445-OJXON4YN751QKWPJUVYY/SC1_22.jpg Blog - SOL CRUSHER V1.0 So after some more research into what people use to drive large LED displays, I came across the Teensy. It runs on the same code as arduino (which I already knew how to use) and is way more powerful. They also sell a shield called the OctoWS2811 which comes with a library for controlling the LEDs and I found examples of people controlling way more LEDs than I needed. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533013436140-XUM1GKXKTY13Q4ZILK9G/SC1_37.jpg Blog - SOL CRUSHER V1.0 Joined by a third! https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009640010-INCPALITG8IYZSCRQUSF/SC1_11.jpg Blog - SOL CRUSHER V1.0 Unfortunately I realized too late that the LED footprint was wrong. I had used the footprint for the WS2812 LEDs, and didn't notice that I ordered the updated WS2812Bs... Completely incompatible but I could still solder the boards together to see how that worked. I also wasn't too happy with the silk screen pattern, so I made some modifications for the next batch. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009541835-CAKT02ORU6EN7BGO4OZO/SC1_9.jpg Blog - SOL CRUSHER V1.0 While the quality and speed are great, this initial prototype run of 6 cost me $60. To get the 180 boards I needed would be way to expensive. Also, OSH only has one thickness option: the standard .062". To save on weight I wanted to get .031" boards. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009392289-Y4MOU06C0PGEA6JOKECO/SC1_7.jpg Blog - SOL CRUSHER V1.0 This was one of the initial versions of the board layout. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009682743-F3Z44YUWE8822YCGSK9G/SC1_12.jpg Blog - SOL CRUSHER V1.0 Along with the prototype boards I also designed and ordered these little guys. It's a low voltage cutoff circuit to protect my LiPo batteries from draining too far. If the batteries ever drop below 3.0V per cell they can be permanently damaged and never hold a charge again. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010544047-58ADRGHVIUHYF9FBI9C8/SC1_16.jpg Blog - SOL CRUSHER V1.0 Speaking of the battery. This is what I'm using. I got 4 10,000 mAh 22.2V LiPo batteries. Each one should last me 5-6 hours depending on the animation, which should be good for two days or more of a festival. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009589535-D6CDVGHCV8FKKQAHEYKL/SC1_10.jpg Blog - SOL CRUSHER V1.0 On the back side you can see how the boards are soldered together. They're actually surprisingly strong! https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533013305498-5LWNVRP9I650ASPE8XQ9/SC1_34.jpg Blog - SOL CRUSHER V1.0 Got a good amount done on this weekend. Lots of time soldering and watching TV. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533013804649-MPOZACMUN3TU2O0V2L74/SC1_42.jpg Blog - SOL CRUSHER V1.0 Even with only half of it done it lights up my room in the daytime. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009296519-8U1OQSIGEFN8ERQK0GP7/SC1_5.jpg Blog - SOL CRUSHER V1.0 The model started to get a lot more complex. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533012234021-5B552KFNUSJ6E2WHTRCW/SC1_28.jpg Blog - SOL CRUSHER V1.0 And the silk screen pattern is much more enjoyable this time around. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533008682834-1RTHYL6UMHMVV9FOKBZO/SolCrusherV1_Title.png Blog - SOL CRUSHER V1.0 This is the build log for my LED totem project. It took months of work to build and I barely got it done in time for EDC 2016. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009466800-TMEE0BII6EZY161MUZAJ/SC1_8.jpg Blog - SOL CRUSHER V1.0 I ordered the prototype boards through OSH Park. They're super fast and high quality and I've used them for several projects now. However they charge $5 per sq. in. and you get 3 boards. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533012938266-UBQIRBV35OA97H99B41I/SC1_31.jpg Blog - SOL CRUSHER V1.0 I 3d printed these brackets for the back side of each panel. It will connect to the fiberglass rods to get support from the core structure. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533013474191-RRVAY7DKBPLVWIPIJ1MN/SC1_38.jpg Blog - SOL CRUSHER V1.0 https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533008843115-ER7NT7QZ31OQ9LM97BNF/SC1_2.jpg Blog - SOL CRUSHER V1.0 But 3 LEDs per panel seemed to look a lot better. And it would give me a lot more resolution to work with. For this project I'm using WS2812 LEDs. They are also known as neopixel LEDs over at Adafruit. The cool thing about these is that they only need a common power and ground and a single data line to chain them together. So instead of needing 3x540 PWM signals from my microprocessor I just need a single pin (I actually divided it up between 4). https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010580722-09U0YBCWPLBVHUYK1WEH/SC1_17.jpg Blog - SOL CRUSHER V1.0 I also had to switch out the connectors on these guys. Doing this made me really nervous. One mistake and I could end up with a MASSIVE fire on my hands. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533008761300-6S13PMX700QNI2WG7REQ/SC1_1.jpg Blog - SOL CRUSHER V1.0 It all started with an idea. What if I made a totem with a ton of LEDs? I did some research on the geometry of geodesic spheres and created a quick mock up in CAD. Originally I was looking at 1 LED per panel. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010731655-0IT0P9UFXP4W744K5YKD/SC1_21.jpg Blog - SOL CRUSHER V1.0 Originally I wanted to use a Raspberry Pi. This would allow me to use processing for the animations, and easily input adjustments in real time using a little bluetooth keyboard. Unfortunately the WS2812 LEDs require pretty precise timing that is hard to achieve on a microprocessor that's also running an operating system. I found a library that supposedly worked but I just couldn't get it running. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009179653-IFBCYL0CQXBQO8NF96KW/SC1_3.jpg Blog - SOL CRUSHER V1.0 I started figuring out LED positioning and how I could have a common power and ground plane across the whole sphere. I did this in solid modeling software because it's a lot easier to make changes with parametric modeling. Circuit board layout programs are a lot less flexible. This side shows the power plane. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010508769-VTR64B8491GH56WU55VS/SC1_15.jpg Blog - SOL CRUSHER V1.0 And I need an extension cord to run to my backpack (where I'm keeping the battery) https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533012076656-Z1TQ7XO373UR209SE8DB/SC1_25.jpg Blog - SOL CRUSHER V1.0 Finally the second batch of boards arrived! It took a lot of searching but I went with Seeed Studio. They're based in China but their prices were really good. I read some concerns about the quality of the boards but I figured my circuits were so simple I didn't have much to worry about. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009350368-4X3SQLSQRDFOXWAYUYMR/SC1_6.jpg Blog - SOL CRUSHER V1.0 And I started work on what would become the internal structure. I couldn't just rely on the solder connections to hold everything together. https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533009234482-4NTITU749N3T8TZFX86F/SC1_4.jpg Blog - SOL CRUSHER V1.0 And this side shows the ground plane and power plane connections (everything is soldered on the back side). https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533010700393-ST8HXLTJK89UKU2GKAOD/SC1_20.jpg Blog - SOL CRUSHER V1.0 Here's the LVC board all closed up and powered! https://images.squarespace-cdn.com/content/v1/5b5fae0a1aef1dbe876b21ba/1533012106863-MP4613S0ENZFN9UW3IEP/SC1_26.jpg Blog - SOL CRUSHER V1.0 I got the entire order of 225 boards for $350 (including shipping) which was way better than I had expected to get. 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