WS2812 LED Solder Jig for round 9mm SMD using 24 AWG Magnet Enamel Wire

prusaprinters

<p>This is a jig that can be used when soldering round SMD mounted WS2812 LED using 24 AWG Magnet Enamel Wire</p><p>I created this jig to assist me in soldering magnet wire to pre-populated WS2812 LED assemblies. &nbsp;</p><ul><li>The jig will hold the LED in the correct orientation with space for the capacitor and resistor that typically are mounted on these small boards. &nbsp;</li><li>If your LED is mounted to the board crooked, it will cause the pads to rotate slightly due to the way the jig is designed. &nbsp;If this happens, simply lift the LED and rotate slightly, but don't try to push down into the jig as this could cause damage to the LED. &nbsp;</li><li>The end of the jig has a cutout that allows you to see if the LED is aligned in the channel and can also be used to pop the LED out when done soldering.</li></ul><p>This design assumes the following:</p><ul><li>You are using 24 AWG enamel coated magnet wire that measures ~0.5mm.&nbsp;</li><li>You are using 9mm round LED assemblies that have been filed so that the profile is smooth. &nbsp;The LED will not seat if the assembly is not round. &nbsp;</li><li>You have a well calibrated printer - you have adjusted your bed leveling, flow settings and e-steps</li></ul><p>Suggested print settings:</p><ul><li>0.4mm nozzle or smaller</li><li>0.1mm - 0.16mm layer height - The lower the layer height the more constant the wire channels will be.</li></ul><p>After printing, I would suggest using an Exacto to clear the channels for the wires, slightly tilting the blade as you go down the channel. &nbsp;This will help to form a “V” shape in the channel, resulting in easier insertion. &nbsp;In the future I will adjust the design to have a semi closed top so that the wires do not come up through the slot, but for now it works well if the wire is straight.&nbsp;</p><p>Prior to soldering, be sure to flux and tin your pads as well as ensure you have removed the enamel from the magnet wire and the wire tip is tinned. &nbsp;When soldering, be sure that you minimize the contact time with the LED to ensure you do not damage the LED.</p><p>The design is made in FreeCAD and can be remixed to suit your needs. &nbsp;</p><p>In the future I will be adding other variations to allow for other wire sizes and LED types (4 wire vs the current 3 wire).</p><p>Please let me know of any suggestion you might have for improvement. &nbsp;</p>