LED Illuminated 3D Letters from Design to Print on PrintUP 3D Channel Letter Printer

Armed with the foundational knowledge from our previous videos on the basics of 3D printing and dual-colour 3D printing, we are now ready to tackle our primary goal: to do the 3D letter channel printing! In this tutorial, we'll walk you through creating a single letter, leveraging the skills you've already acquired.
Setting Up the Design
Choosing Your Design Software:
Depending on the software you have (such as CorelDRAW or Adobe Illustrator), you will begin by creating your vector-based design. If you don't have access to these, you can use TinkerCAD, a free online 3D modelling tool.
Creating the Letter:
Open your chosen program and use the text tool to type out the letter or word you need. For simplicity, we’ll use the letter “L.”
Select an appropriate font that is clear and straight-edged to make the process easier.
Resizing the Letter:
Adjust the size of your letter to suit your printing requirements. Start by making it large enough to work with and later scale it down to the desired size.
Designing the Channel
Creating the Base:
Reduce the height of your letter to create a base layer. This base will support the letter and house the LED strip.
Ensure the letter is sufficiently large to accommodate the LED strip.
Making Entry and Exit Points for LEDs:
Add entry and exit holes in your design for the LED strip. These should be large enough to fit the strip comfortably. Typically, a 5mm opening works well for standard LED strips.
Use TinkerCAD’s hole tool to create these openings, ensuring they are aligned with the design’s requirements.
Building the Sidewalls:
Duplicate the letter and create sidewalls. Adjust the height to create a boundary that will contain the LEDs.
Align the new shape with the base layer and ensure it’s the correct height to house the LED strip.
Creating the Channel Inside the Letter:
Create an inner channel by adding another layer inside your letter. This channel will house the LED strip and guide the light.
Ensure the channel is proportionate and properly aligned within the outer walls.
Final Adjustments
Grouping and Punching Out Sections:
Group the designs and punch out the necessary sections to ensure the channel is hollow and ready for the LED strip.
Make sure the punched-out sections are precise and clean.
Creating the Top Layer:
Design a top layer that will cover the letter after the LEDs are installed. This layer can be printed separately and glued on top.
Consider using translucent filament for the top layer to diffuse the LED light effectively.
Preparing for Print
Exporting the STL Files:
Export the base and top layer designs as STL files from your design software.
Open these files in your slicing software (such as Cura) and prepare them for printing.
Setting Up in Cura:
Load your STL files into Cura and ensure everything is correctly scaled and positioned.
Use the support blocker tool to manage where colour changes will occur if you’re using dual-colour printing.
Configuring Colour Changes:
In Cura, select where you want the colour changes to occur. This can be done by adding a support blocker and modifying it to define different colour regions.
Ensure the correct colours are loaded into your printer before starting the print.
Printing the Design:
Start the print and monitor it to ensure everything is proceeding smoothly. Pay attention to the colour changes and the integrity of the structure.
Post-Processing
Cleaning Up the Print:
Once the print is complete, clean up any excess plastic or stringing using clippers or cutters.
Sand any rough edges to ensure a smooth finish.
Assembling the Components:
Place the LED strip into the channel, ensuring it fits snugly and runs through the designated entry and exit points.
Attach the top layer by gluing it onto the base. Ensure it’s securely in place and properly aligned.
Finishing Touches:
Sand the entire piece for a smooth finish. Optionally, you can paint the letter for a glossy effect or to match a specific colour scheme.
By following these steps, you’ll have a fully functional 3D letter with an integrated LED channel, ready for display. For more detailed settings and configurations, refer to our previous videos on 3D printing basics and dual-colour printing. Happy printing!
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