Innovation Lightbulb Badge - Touch-Activated RGB LEDs

🏆 My entry for the PCBWay 11th Design Contest: "11 Years of Innovation and Beyond with PCBWay"

Overview

A creative lightbulb-shaped badge featuring touch-activated LED animations, combining PCB art with functional electronics. The badge celebrates PCBWay's 11-year journey with an interactive cog/gear LED pattern that comes to life when you touch the golden snake base.

The completed Innovation Lightbulb Badge showcasing PCBWay's precision manufacturing. Animation video here

🌟 Features

Touch Activation: 28 cog/gear LEDs illuminate when touching the golden snake base
Multiple Animation Modes: 5 different color patterns including rainbow, PCBWay green, fortune red, Australian colors, and white
Rotating Animation: LED pattern simulates a turning gear/cog mechanism with configurable speed
Cultural Integration: Year of the Wood Snake (2025) with bamboo and Chinese pine tree artwork
PCB Art: Complex lightbulb cutout showcasing PCBWay's precision manufacturing and UV print capabilities
Low Power Design: Battery-efficient with automatic sleep mode when not in use
Mode Cycling: Automatically cycles through different color themes every 10 seconds of use
Interactive Badge: Encourages human connection and conversation
Open Source: Full KiCad files, firmware, and documentation shared with the maker community

🔧 Hardware Requirements

Main Components

PCB: Custom lightbulb-shaped design (order from PCBWay)
Microcontroller: STM8S003F3P6 (20-pin TSSOP package)
LEDs: 28x WS2812B addressable RGB LEDs (32 configured in firmware for animation wrapping)
Power: LiPo battery (recommended: 503035 or 602535 with protection circuit)
Touch Sensor: Golden snake pads (built into PCB design)

Additional Components

See /Hardware/BOM.csv for complete bill of materials including:

Voltage regulators and power management ICs
Capacitors and resistors
Battery charging circuit components
Programming header components

Tools Required

Programming: ST-Link v2 programmer (or compatible)
Soldering: Hot air rework station, solder paste, flux
Assembly: Fine-tip tweezers, magnifying glass
Power: 3.3-5V power supply or LiPo battery

🚀 Getting Started

Prerequisites

Software Requirements

Arduino IDE 2.0 or later
STM8 Arduino Core: Add https://github.com/akashkapashia/stm8_arduino/raw/master/package_sduino_stm8_index.json to Board Manager URLs
ST-Link Drivers: Install ST-Link v2 drivers for your operating system

Hardware Requirements

ST-Link v2 programmer
4-wire connection: RST, GND, SWIM, 5V
Power source (battery or bench supply)

Assembly Instructions

Ordering PCB from PCBWay

Option 1 - KiCad Plugin (Recommended)

Download the complete /Hardware/KiCad Files/ folder
Open PCBWay_11th_Design_Contest.kicad_pro in KiCad 9 or later
Use the PCBWay plugin to order directly from KiCad
Select UV printing option for the artwork layers

Option 2 - Manual Gerber Upload

Visit PCBWay.com
Upload /Hardware/Gerbers.zip
Important: Request UV printing for the artistic layers
Optional: Upload /Hardware/BOM.csv and /Hardware/Centroid.pos for assembly service

Option 3 - Shared Project

Order from the PCBWay Shared Projects Page

Soldering Process

⚠️ Important Soldering Order:

Front LEDs First: Apply solder paste and reflow the 28 WS2812B LEDs on the front
Back SMD Components: Apply solder paste and reflow all SMD components on the back
Edge Components: Use hot air gun for edge-mounted components (decoupling capacitors, if used)

Key Soldering Notes

LED Capacitors: Optional but recommended for stable operation
R4 (0Ω Resistor): Can be used to force-enable LEDs for testing (bypasses touch sensor)
Programming Pads: Ensure clean connections for reliable programming

Programming Setup

Connection Diagram

ST-Link v2   →    Badge Programming Pads
-----------         ----------------------
/5V          →     5V  (marked with [])
GND          →     GND (marked with ())
SWIM         →     SWIM (marked with ())
NRST         →     RST (marked with ()))

Programming Pad Layout

Top of bulb shape

( ) RST    - Reset pin
( ) GND    - Ground
( ) SWIM   - Single Wire Interface Module
[ ] 5V     - Power supply (square pad)

Bottom of bulb / thread

Installation

Method 1 - Arduino IDE (Recommended for Development)

Clone the repository:

git clone https://github.com/platima/PCBWay-11th-Design-Contest.git
cd PCBWay-11th-Design-Contest

Install STM8 Arduino Core:
- Open Arduino IDE
- Go to File → Preferences
- Add board manager URL: https://github.com/akashkapashia/stm8_arduino/raw/master/package_sduino_stm8_index.json
- Go to Tools → Board → Board Manager
- Search for "STM8" and install the package
Configure Board Settings:
- Board: "STM8S103F3"
Upload Firmware:
- Open Firmware/firmware.ino
- Connect ST-Link to programming pads (or hold in place)
- Click Upload

Method 2 - Pre-compiled Hex File (Quick Start)

Download and extract: firmware.ino.hex.zip
Obtain stm8flash: from https://github.com/vdudouyt/stm8flash

Flash using stm8flash:

stm8flash -c stlinkv2 -p stm8s003f3 -w firmware.ino.hex

🎨 How It Works

System Architecture

The badge operates in two distinct modes based on touch sensor input:

1. Standby Mode (Power Saving)

All LEDs Off: Conserves battery power
Touch Monitoring: ADC continuously samples the golden snake pads
Low Power: Minimal current draw for extended battery life
Wake-up Ready: Instantly responds to touch detection (150ms)

2. Active Mode (Animation Running)

Touch Detected: ADC reading exceeds 800mV threshold
LED Animation: Cog/gear pattern with rotating effect
Mode Cycling: Automatically changes color themes every 10 seconds
Continuous Operation: Runs until touch is no longer detected

3. Touch Sensor Technology

Resistive Touch: Uses skin conductivity to detect finger presence
Golden Snake Pads: Artistic PCB traces serve as touch electrodes
ADC Monitoring: STM8's built-in ADC on PD5 measures voltage changes
Threshold Detection: 800mV threshold provides reliable touch detection

4. LED Animation System

Cog/Gear Pattern: 28 LEDs arranged in 14×2 tooth configuration
Rotating Effect: Pattern shifts by 2 LEDs every 200ms
Color Modes: 5 different themes with smooth transitions
Modular Design: 32 LEDs configured in firmware for seamless wrapping

⚙️ Configuration

Animation Timing

#define ANIMATION_DELAY 200     // Animation speed (200ms = 5 FPS)
#define MODE_CHANGE_MS  10000   // Mode change interval (10 seconds)

Cog Pattern Settings

#define TOOTH_SIZE      4       // LEDs per color segment
#define TOOTH_GAP       4       // Gap between segments  
#define SHIFT_AMOUNT    2       // Animation shift speed (LEDs per frame)
#define N_LEDS          32      // Total LEDs (28 physical + 4 for wrapping)

Touch Sensitivity

#define TOUCH_THRESHOLD_MV 800  // Touch threshold (800mV)
#define ADC_VREF_MV     4100    // Reference voltage (4.1V)
#define ADC_RESOLUTION  1023    // 10-bit ADC resolution

Visual Settings

#define BRIGHTNESS      64      // LED brightness (0-255, set to 25%)

🎨 Animation Modes

The badge features 5 distinct animation modes that cycle automatically:

1. Rainbow Mode (`MODE_RAINBOW`) - Default

Colors: Full spectrum rainbow cycling
Pattern: Each LED position gets a different hue
Effect: Creates a vibrant, eye-catching display
Use Case: General demonstration and attraction

2. PCBWay Mode (`MODE_PCBWAY`)

Colors: PCBWay signature green (RGB: 17, 167, 59)
Pattern: Solid green cog rotation
Effect: Brand-themed animation
Use Case: PCBWay events and demonstrations

3. Fortune Mode (`MODE_FORTUNE`)

Colors: Traditional Chinese red
Pattern: Solid red cog rotation
Effect: Cultural significance for good fortune
Use Case: Chinese New Year, cultural events

4. Australia Mode (`MODE_AUSTRALIA`)

Colors: Green and gold alternating
Pattern: Alternating national colors
Effect: Patriotic themed display
Use Case: Australian events (customizable for other countries)

5. White Mode (`MODE_WHITE`)

Colors: Pure white
Pattern: Clean, bright white cog
Effect: Professional, elegant appearance
Use Case: Formal events, demonstrations

⚡ Power Management

Battery Specifications

Recommended: 503035 (500mAh) or 602535 (600mAh) LiPo
Voltage: 3.7V nominal (3.0V - 4.2V range)
Protection: Built-in PCM (Protection Circuit Module) required

Power Consumption

Standby Mode: <1mA (touch sensor monitoring only)
Active Mode: ~200mA (all LEDs at 25% brightness)
Battery Life:
- Standby: Several days
- Continuous use: 2-3 hours
- Typical use (intermittent): 8-12 hours

Charging

Use external charger such as LiPo Charger Module (Basic)

🔨 PCB Design

Design Features

Artistic Shape: Lightbulb cutout showcasing PCB manufacturing precision
LED Layout: 28 WS2812B LEDs arranged in perfect cog/gear pattern
Touch Pads: Golden snake design serves as capacitive touch sensor
Cultural Elements: Year of the Wood Snake 2025 artwork
Functional Art: UV printing demonstrates PCBWay's advanced capabilities

Technical Specifications

Dimensions: 58.74mm wide, 98.5mm tall
Layers: 2-layer PCB with artistic copper pours
Thickness: 1.2-1.6mm standard PCB thickness (FR4)
Surface Finish: ENIG for golden appearance, else HASL
UV Printing: Multi-color artwork on solder mask

Programming Interface

Connector: 4-pin programming header
Layout: RST, GND, SWIM, 5V
Access: Easily accessible on PCB back
Protection: Test points for reliable connection

📈 Performance

Response Characteristics

Touch Response: <50ms from touch to LED activation
Animation Frame Rate: 5 FPS (200ms per frame)
Color Accuracy: 24-bit RGB with gamma correction
Power Efficiency: >99% idle time power savings

Environmental Specifications

Operating Temperature: -10°C to +60°C
Storage Temperature: -20°C to +80°C
Humidity: 0-95% non-condensing
Vibration: Suitable for badge/wearable use

Recommendations

Battery: Use velcro or similar adhesive to attach LiPo to back of PCB

🛠️ Troubleshooting

LED Issues

Problem: LEDs don't light up Solutions:

Check power supply voltage (minimum 3.5V for WS2812B)
Verify solder connections on data line (PD4)
Test with multimeter: 5V, GND, and data signal
Ensure correct LED orientation (check datasheet pin 1)

Problem: Some LEDs don't work Solutions:

Check for cold solder joints on faulty LEDs
Verify data chain continuity (WS2812B are daisy-chained)
Test individual LED with reduced brightness
Replace faulty LEDs if necessary

Touch Sensor Issues

Problem: Touch sensor not responding Solutions:

Verify ADC configuration and PD5 connection
Check threshold setting (try lowering TOUCH_THRESHOLD_MV)
Clean golden snake pads (remove oxidation/contamination)
Test with multimeter: voltage should change when touched
Populate R4 (0Ω) to bypass touch sensor for testing

Problem: Touch sensor too sensitive Solutions:

Increase TOUCH_THRESHOLD_MV value
Check for electrical noise affecting ADC
Ensure proper grounding of the badge
Add filtering capacitor if needed

Programming Issues

Problem: Cannot program STM8 Solutions:

Verify ST-Link connections (RST, GND, SWIM, 5V)
Check ST-Link driver installation
Ensure 5V power supply to badge during programming
Try different programming cable/connection
Reset STM8 before programming attempt

Problem: Code compiles but doesn't run Solutions:

Verify clock configuration (16MHz HSI)
Check for infinite loops in initialization
Add debug outputs to identify where code stops
Verify all peripheral configurations

Animation Issues

Problem: Animation stuttering or irregular Solutions:

Reduce ANIMATION_DELAY for smoother motion
Check power supply stability (use oscilloscope)
Verify timing calculations in animation code
Ensure adequate power supply current capability

Problem: Wrong colors or color order Solutions:

Verify COLOR_ORDER setting (should be grb for WS2812B)
Check LED manufacturer specifications
Test with simple solid colors first
Verify RGB color calculations in mode functions

🚧 Future Enhancements

Community Contributions

Pattern Library: User-submitted animation patterns
3D Printed Case: Protective housing with lanyard attachment
Alternative Themes: Country-specific color schemes
Educational Modules: Programming tutorials and exercises
Hardware Variants: Different LED counts and arrangements

Advanced Features

Battery Monitoring: Visual battery level indication
Event Modes: Special patterns for holidays and events
Diagnostic Mode: Self-test and troubleshooting features

📋 Version History

Version 3.0 (Current - June 2025)

✅ Touch sensor functionality with ADC-based detection
✅ Five animation modes with automatic cycling
✅ Low-power sleep mode implementation
✅ Optimized cog/gear animation with smooth rotation
✅ Battery-efficient operation with wake-on-touch
✅ Complete STM8 Arduino IDE integration

Version 2.0 (Development)

✅ STM8 microcontroller port completion
✅ WS2812B LED driver optimization
✅ Basic animation patterns implementation
✅ PCB design refinement and testing

Version 1.0 (Prototype)

✅ Initial WS2812 control implementation
✅ Basic LED functions and color control
✅ Proof-of-concept hardware design

🤝 Contributing

This project is part of the PCBWay 11th Design Contest and is open source for the maker community!

How to Contribute

Fork the repository on GitHub
Create a feature branch (git checkout -b feature/amazing-feature)
Make your changes with clear commit messages
Test thoroughly on actual hardware if possible
Submit a pull request with detailed description

Contribution Guidelines

Code Style: Follow existing Arduino/C++ conventions
Documentation: Update README and code comments
Testing: Verify changes don't break existing functionality
Hardware: Test on actual badge hardware when possible

Areas for Contribution

New Animation Modes: Creative LED patterns and effects
Power Optimization: Extend battery life further
Code Optimization: Improve performance and memory usage
Documentation: Tutorials, guides, and examples
Hardware Variants: Alternative designs and improvements

📄 License

This project is licensed under the MIT License - see the LICENSE file for details.

License Summary

✅ Commercial use permitted
✅ Modification and distribution allowed
✅ Private use encouraged
❌ No warranty provided
📝 License and copyright notice required

🙏 Acknowledgments

Special Thanks

PCBWay for hosting the 11th Design Contest and providing exceptional PCB manufacturing services
akashkapashia for maintaining and improving the STM8 Arduino core library
ctxz for the excellent TinyWS2812 library that makes WS2812B control seamless
STMicroelectronics for the robust and affordable STM8 microcontroller platform
Adafruit for pioneering WS2812 integration and providing extensive documentation
Wifey for her patience with my stress, design and symbolism input, and feedback

Community Support

EEVblog Forum for embedded systems design discussions
Arduino Community for programming support and examples
KiCad Community for PCB design tools and libraries
GitHub Contributors for code reviews and improvements
Maker Community for inspiration and creative ideas

Technical Resources

STM8 Reference Manual for comprehensive hardware documentation
WS2812B Datasheet for LED timing and electrical specifications
PCB Manufacturing Guidelines from PCBWay for design optimization
Embedded Systems Tutorials for low-power design techniques

📞 Contact

Project Information

GitHub Repository: PCBWay-11th-Design-Contest
Author: @platima (PlatimaTinkers)
Contest: PCBWay 11th Badge Design Contest 2025
Theme: "11 Years of Innovation and Beyond with PCBWay"

Support and Questions

Issues: GitHub Issues
Discussions: GitHub Discussions
Email: [Contact through GitHub profile]

Name		Name	Last commit message	Last commit date
Latest commit History 47 Commits
Datasheets		Datasheets
Firmware		Firmware
Hardware		Hardware
Images		Images
LICENSE		LICENSE
README.md		README.md
Schematic.pdf		Schematic.pdf
Submission.pdf		Submission.pdf
firmware.ino.hex.zip		firmware.ino.hex.zip

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platima/PCBWay-11th-Design-Contest

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