1. Begin on the reverse side.
2. Tin one of the pads for each resistor and also for the capacitor.
I find it easiest to use 0,3-0,4mm leaded solder.
3. Reheat the solder with the soldering iron and place the correct
component into the melted solder.
4. Solder the other end of all the components.
5. Turn the board over.
6. Tin one of the pads for each LED, i suggest the pad in contact with
the copper plane like in the picture.
7. LEDs usually have some kind of marking to show their polarity, at
least on the bottom but often also on the top. All the LEDs in the
picture are turned with the cathode down.
8.LEDs where markings are missing or hard to see can be tested by
using a multimeter. The multimeter is set to diode test mode and the
probes are touched to the connections on the LED. In this picture the
black probe (negative) is on the lower side and the red probe (positive)
is on the upper side.
9. Solder all the LEDs with the anode towards the copper plane. All the
LEDs in the picture are turned with their cathode marking away from the
10. Solder the other end of all the LEDs.
11. You can now test run the badge by setting the voltage of a lab
power supply to 3-5V and the current to zero. Connect test according
to the picture and turn the current limit up very carefully. If the
badge draws more than 0,1A something is wrong, for example a short
in a solder joint.
12. Straighten the 4 circular wire pieces and solder them according to the picture.
13. Mount the single sided copper board with 4 holes according to the
picture. Note how two of the holes has the copper removed around them.
**Note: the updated version has a proper PCB instead of this hand made board.**
14. Place a CR2032 or other 3,2mm thick 20mm diameter object according
to the picture.
15. Mount the last PCB according to the picture, note that the two
square areas should be turned outward and oriented so they are on
the top when the badge is observed vertically from the front.
The wires are then lightly tightened and bent over to keep the
boards in place.
16. Solder the 4 wires to the back PCB.
17. Solder 2 of the 4 wires to the single sided board, note that you should
only solder the holes where the copper comes all the way up to the wire.
**Note: on the updated version with the proper middle PCB all 4 holes should be soldered.**
18. Cut off any protruding wire ends.
19. Solder the brooch pin in place. If desired the pin carrier can be
cut in two to be used as a switch, note that about 2-4mm of the center
of the carrier needs to be removed to allow for a gap in the middle. DO
NOT use delicate electronics cutters for this, use proper heavy gage cutters.
If the pin carrier is not cut in two the badge is instead turned off by
removing the battery.
Wear the badge in a visible location and use a non-depleted battery
at every following student event!
Latest update 2016-11-19