Creative Pogo LED Lighting - Modular Plug-in LED Boxes

Hi everyone! Welcome to my latest project: a modular, plug-in LED lighting system that is as fun as it is functional! Using 3D-printed square cases, magnetic pogo pin connectors, and addressable LEDs, I created a customizable lighting solution perfect for your desk, wall or even just for decoration. Powered by just 5 volts and controlled via Wi-Fi with the app, this project blends simplicity and creativity. Stick around to see how it all comes together step by step. Let's get started!

Here are the hardware and components used in the project:

1. 3D printed boxes (STL files in the next step)
2. WS2812B LED Strip (Approx. 60 LEDs - 110 centimeters)
3. 3-Pin 2.54mm Pogo Pin Magnetic Connector (2 pair set)
4. 8x1.5mm Neodymium Magnet (8 pcs.)
5. 5V 2.5 Amps Power Adapter
6. Wemos D1 Mini ESP8266 WiFi Board
7. Wire and Heat Shrink Tubing
8. Printed Circuit Board (Thanks for the support of PCBWay)
9. 1000uF Capacitor
10. 330Ω Resistor
11. 5.0-2Pin Terminal Connector
12. 5.0-3Pin Terminal Connector

For this project, I designed 3 square-shaped boxes, but I am thinking of designing cases in different shapes such as triangles and I aim to create different patterns by combining more cases in the coming days. Of course, I will need to make some updates to the circuit for this.

The pogo pins used in the project are winged and I obtained them from a local store, I created the design accordingly. But I have also added STEP extension files in case you want to make changes, so you can update the design as you wish.

The display, which is the side that reflects the LED lights, is 1 millimeter thick and I think it was enough to create a dim view.

I used Bambu Lab A1 Combo as the printer and Esun brand Snow White as the filament. I printed the prints in Standard, i.e. medium quality.

WS2812B LED is preferred in the project. The WS2812B is a popular addressable LED that integrates RGB LEDs and a control chip into a single package. The LEDs are daisy-chained, meaning a single data line (DIN) can control an entire strip or matrix of LEDs. This makes them perfect for projects requiring dynamic lighting effects, animations, or custom patterns.

The project involves modular square boxes connected via Pogo pins for power and signal transmission. Here’s how the WS2812B LED strip signal flow is organized:

1. The main box houses a control circuit board on one side. Two 8-LED strips are installed inside this box, one on the right side and the other on the left side. The DIN (Data Input) of these LED strips is connected directly to the circuit board, where the data signal originates. The LED strips are arranged vertically along the box edges, and their DO (Data Output) terminals mark the end of each strip.
2. The DO signal and power lines from both strips are connected to pogo pins located on the right and left sides of the main box. These pogo pins serve as connectors to the neighboring boxes, enabling seamless power and signal transfer.
3. The right and left boxes receive the DIN signal and power through the pogo pins. Each of these boxes contains a single 22-LED strip, starting with the DIN terminal. The LED strips are arranged to wrap around the edges of these boxes, forming a continuous lighting pattern.

This modular design allows the signal to flow smoothly from the main box to the side boxes, enabling synchronization of the LED animations across all connected units. The pogo pins ensure a reliable and compact connection, making the system easy to assemble and expand.

Note: I have marked the start (DIN) and end (DO) positions in the attached images.

In the previous step, we determined the required LED strip lengths and signal flow direction for the modular boxes. We will focus on installing two 3-pin magnetic pogo-pin female connectors on the main box (center box) and connecting the LED strips.

Prepare the LED Strips:

Remove the LED strips for the right and left sides of the main box. Solder three wires to the DIN (Data In) and DO (Data Out) terminals for each strip. These wires need to be longer to reach the bottom and sides of the main box.

1. LED starting point (DIN) will be the bottom side (this is the side where the circuit board is located)
2. The LED endpoint (DO) will be the top side. From this side, it will be connected to the Pogo pins on the right-left side of the box with wire.

Connect the wires to the Pogo Pins:

Once the wires are soldered to the LED strips, connect the wires coming from the DO terminal of the LED strips to the pins on the pogo connectors respectively. Use heat shrink tubing to insulate the soldered connections and prevent accidental contact between the wires.

Insert the LED Strips and Pogo Pins:

Insert the pogo pin connectors into the designated slots on the right and left sides of the main box. Secure the LED strips starting from the DO terminal (top of the main box) and insert them along the edges towards the DIN terminal (bottom).

With the pogo pins and LED strips in place, the main box assembly is now complete. The pogo pins are ready to transmit power and signals to the side boxes.

In the next step, we will install the pogo pin connectors for the right and left boxes to complete the modular system.

In this step, we will assemble the two side boxes that connect to the main box. Each side box uses a 22-LED strip and is designed to integrate with the modular system via pogo pin connectors seamlessly.

Prepare the LED Strips:

Each side box is equipped with a 22-LED strip. Start by soldering male pogo pins to the DIN (Data In) terminal of the LED strip. Ensure that the pin order matches the female pogo pins in the main box. This alignment is critical for proper signal and power transfer.

1. The DO (Data Out) terminal of the LED strip is left unused in these boxes.

Insert Pogo Pins:

Once the male pogo pins are soldered to the LED strips, insert them into the designated pogo pin slots of the side boxes. Double-check that the pin alignment matches the female connectors in the main box. Proper alignment ensures a reliable connection and prevents potential mismatches.

Position the LED Strips:

Secure the LED strips along the inner walls of each side box, wrapping them neatly around the edges. This arrangement provides even illumination and maintains the modular aesthetic of the design.

Enhance Magnetic Connectivity:

Although the pogo pins have built-in magnets, additional stability is achieved by adding two 8x1.5mm Neodymium Magnets on each side of the box where the connectors are located. These magnets ensure a secure and tight connection between the boxes.

1. Pay close attention to the polarity of the magnets during installation to ensure they attract rather than repel.

Finalize the Assembly:

With the pogo pins and LED strips installed, and the magnets securely in place, the side boxes are now ready to attach to the main box. The modular system is designed to enable seamless power and signal transfer through the pogo pins, while the magnets provide a firm and stable connection.

In the next section, we will assemble the circuit board and connect the LED strips.

In this step, we focus on the custom-designed PCB that powers the main box and ensures the smooth operation of the LED strips and Wi-Fi control. Here’s a detailed breakdown of the process:

Components Used in the Circuit:

The custom PCB is designed to host essential components for powering and controlling the LED system:

1. Wemos D1 Mini ESP8266 WiFi Board: Serves as the microcontroller with Wi-Fi capabilities for remote control.
2. 1000uF Capacitor: Stabilizes the power supply for the LEDs.
3. 330 Ohm Resistor: Protects the LED signal line and ensures proper data transmission.
4. 3-Pin Terminal Block Connector: Facilitates connections for LED power (5V), ground (GND), and signal (DIN).
5. 2-Pin Terminal Block Connector: Provides a power input for the PCB.
6. 5V 2.5A Adapter: Supplies power to the circuit.

Why a Custom PCB?

While the circuit can be built on a breadboard, a custom PCB offers greater stability, professional aesthetics, and compatibility with the main box. For this project, I designed a 2-layer PCB with dimensions of 50x36mm, perfectly fitting into the main box’s PCB slot. The PCB was manufactured by PCBWay, known for high-quality, low-price PCB prototyping. If you’re looking for a reliable PCB manufacturer, I highly recommend PCBWay for your projects. A big thank you to PCBWay for supporting this build!

1. The Gerber file required to obtain the PCBs and more details can be found on this page: https://www.pcbway.com/project/shareproject/Creative_Pogo_LED_Lighting_Design_93642c47.html

Key Features of the PCB:

1. Compact Design: The PCB dimensions ensure it fits snugly into the main box.
2. Component Placement: The LED signal line is connected to GPIO12 (D6), with a 330 Ohm resistor inline. The capacitor stabilizes the power line.
3. Clear Markings: Input/Output terminals and component labels are clearly marked on the top layer for easy assembly.

Assembly Process:

Soldering the Wi-Fi Board:

1. To reduce the PCB’s profile and minimize shadowing within the main box, the Wemos D1 Mini is soldered directly onto the PCB without female headers.

Mounting Other Components:

1. Place the capacitor, resistors, and terminal blocks in their designated spots on the PCB. Basic soldering skills are sufficient for this assembly.

Testing the PCB:

1. Before installing the PCB in the main box, connect it to your computer via USB and upload the LED control software.

Installing WLED Software:

For LED control, I chose the WLED application, a popular and user-friendly tool for addressable LEDs.

1. Visit the WLED Install page - https://install.wled.me/
2. Click “Install” and select the USB port where your PCB is connected.
3. After the installation completes, set up your Wi-Fi credentials.

Once the software is installed and configured, the PCB is ready for connection.

Connecting the Circuit:

Power Connection:

1. Carefully connect the 5V and GND terminals of the power supply to the PCB.

LED Connections:

1. Combine the 5V, GND, and signal wires of the main box LED strips and attach them to the corresponding terminals on the PCB.

Final Placement:

1. Secure the PCB inside the main box and ensure all connections are tight and secure.

With the PCB assembly complete, we are ready for the next step—testing the circuit and LED functionality.

After assembling all the components and making the necessary connections, it’s time to bring the project to life! Follow these steps to power up your creation and customize the lighting setup:

Powering On

1. Connect the 5V 2.5A power adapter to a power outlet.

2. The LED strip in the main box will light up with a default single color, indicating that the system is active.

Connecting via WLED

1. Open the WLED app on your phone or a web browser.

2. In the app, click Discovery Lights.

3. When the app displays “Found WLED,” click the Okay button.

4. You will see the WLED module listed with its IP address—this is your device, ready to be controlled!

Configuring WLED

1. Tap on your device in the app to open its control panel.

2. Navigate to LED Preferences and select:

1. LED Type: Set this to WS281x (compatible with WS2812B LEDs).
2. LED Count: Enter the total number of LEDs in your setup (e.g., 22 for the side boxes plus 16 for the main box, totaling 38 LEDs).
3. GPIO Pin: Set the data pin to GPIO12 (D6).

3. Take some time to explore the settings in this menu for further personalization. Adjust brightness, colors, and other preferences.

4. Once all configurations are complete, press Save and return to the main screen.

Playing with Light Effects

1. Use the app to explore a variety of lighting effects and scenes.
2. Attach the side boxes to the main box using the magnetic Pogo pin connectors, and enjoy the mesmerizing effects as the modular system comes to life.

Thank You!

Congratulations, your modular LED lighting project is complete! Thank you for reading. If you enjoyed this guide, please like and follow to support more projects like this. Feel free to share your thoughts and questions in the comments section—I’d love your feedback!

How to Improve This Project

If you’re interested in taking this project further, here are some ideas for enhancements:

1. Expandability:

1. Add more boxes to create intricate designs and patterns.
2. To support larger setups, consider using 3 or 4 GPIO pins for additional signal outputs. Using a single GPIO pin for too many LEDs can weaken the signal and cause inconsistencies.

2. Segment Control:

1. WLED offers a Segment feature in the “LED Preferences” menu. This allows you to assign different GPIO pins to distinct LED groups (segments), enabling independent control of each segment. You can synchronize or create unique effects for each group.

3. Alternative Shapes:

1. Instead of squares, experiment with triangular modules or other geometric designs.

This modular system is highly versatile, and with some creativity, you can adapt it to various applications. Let me know how you enhance your setup or what you’d like to see next. Stay creative, and happy making!