# Light-Up Costumes in Harsh Environments ## Overview https://www.youtube.com/watch?v=0GtI38EEWDQ Light-up costumes using LEDs are delicate. Wires break, connectors, fail, and dust or water can get into the tiniest cracks in your enclosure, causing short circuits or rust. And yet, most of our LED costumes are dreamed up, built, and created to be taken into harsh environments. We want to wear them to festivals in the desert and have them glow all night. We want to dress our wiggling, squirming kids up in lights so they can trick-or-treat on Halloween Night. We need our costumes or art cars to stand up to assault by excited bystanders who can't resist poking, touching, and tugging on our beautiful creations. They need to be able to weather windstorms and rainstorms, long hugs from strangers in the dark, immersion in cuddle puddles, or pole dances on a moving art car, deep in the playa. They need to work every time we turn them on, without an hour's worth of repairs needed after every appearance. This tutorial will give tips and tricks on design, build, and maintenance for costumes that Will Not Break. I'm using my favorite example: my light-up swimming mermaid tail. You think the playa is a challenge? Try wearing your LED costume in the ocean.  ![LED Mermaid Glimmer](https://cdn-learn.adafruit.com/assets/assets/000/116/351/medium800/projects_glimmer_tank-12.jpg?1667150490) ### Disclaimer I'll be honest.. this guide goes a bit overboard in terms of durability. Most readers don't actually plan to submerse their costume in salt water, and you, gentle readers, are wiser than me. Making a swimmable light-up mermaid tail is a pie-in-the-sea project, and even with all these precautions, my Mermaid Glimmer tail is still a nightmare to keep running. LED projects are salty beasts. Wearing batteries underwater is dangerous. Doing professional performances is very stressful when I'm never 100% sure the tail is going to light up at all, or stay lit in the water for even half an hour. I've spent countless hours repairing and replacing wires and lights and controllers that got wet because I didn't close my case properly, or simply wore out because salt water is very hard on electronics.  This guide will impart some of the knowledge I've gained from years of trying to do the impossible: swim around in the sea with lights on. But all of it will translate into very robust and durable land-based costumes. ### Difficulty Since this guide focuses on durability, I'm keeping the wiring and coding as simple as possible. You will need [rock-solid soldering skills](https://learn.adafruit.com/make-it-glow-how-to-solder-neopixels-a-beginners-guide), and a good healthy dollop of patience. A little extra time and care during the build process will save you hours of repair time down the road. Your project can be as simple or complex as you make it, but remember: the more fancy elements you add, the more potential failure points you have.  ## Controller I'm using a tiny [QT Py ESP32 Pico](https://www.adafruit.com/product/5395) for my project. It doesn't have a lot of extraneous bits or sensors, and it's really small and affordable, so if it gets fried, I can replace it fairly easily. It works with WLED software, which is really easy to install and use to create complex light animations, even if you're not a coder. If you want to add sensors or interactivity, [check out the Adafruit line of Feather boards](https://www.adafruit.com/category/943).  ### Adafruit QT Py ESP32 Pico - WiFi Dev Board with STEMMA QT [Adafruit QT Py ESP32 Pico - WiFi Dev Board with STEMMA QT](https://www.adafruit.com/product/5395) This dev board is like when you're watching a super-hero movie and the protagonist shows up in a totally amazing costume in the third act and you're like 'OMG! That's the hero and they're here to kick some serious butt!" but in this case its a... Out of Stock [Buy Now](https://www.adafruit.com/product/5395) [Related Guides to the Product](https://learn.adafruit.com/products/5395/guides) ![Angled shot of purple square-shaped microcontroller.](https://cdn-shop.adafruit.com/640x480/5395-00.jpg) ### Part: USB C cable quantity: 1 USB C Cable for Programming [USB C cable](https://www.adafruit.com/product/4474) If your project is using NeoPixel strips, Adafruit carries this handy BFF "backpack" that attaches to the QT Py with headers, and gives you a handy port for plugging in your lights. ### Adafruit NeoPixel Driver BFF Add-On for QT Py and Xiao [Adafruit NeoPixel Driver BFF Add-On for QT Py and Xiao](https://www.adafruit.com/product/5645) Our QT Py boards are a great way to make very small microcontroller projects that pack a ton of power - and now we have a way for you to quickly add a [strand of NeoPixels](https://www.adafruit.com/category/168) with a 5V level shifter and a detachable JST PH connector. It's an... In Stock [Buy Now](https://www.adafruit.com/product/5645) [Related Guides to the Product](https://learn.adafruit.com/products/5645/guides) ![Video of a driver board lighting up an RGBW half-meter long LED strip.](https://cdn-shop.adafruit.com/product-videos/640x480/5645-02.jpg) ## Lights I'm using NeoPixel Dots for my project. The dots come in 2" or 4" spacing, and come 20 to a strand.  You could also use NeoPixel strips, rings, or any of the [huge variety of NeoPixel formats Adafruit carries](https://www.adafruit.com/category/168) in your costume. But in my experience, strips break. They are flexible in one direction but very delicate in every other direction.  Rings are sturdy but the connections are tiny, and tend to break also. These NeoPixel dots are potted in resin and wired up with very strong silicone-coated wire. They are very hard to break. It's possible, but you really have to work at it. ### Adafruit NeoPixel LED Dots Strand - 20 LEDs at 2" Pitch [Adafruit NeoPixel LED Dots Strand - 20 LEDs at 2" Pitch](https://www.adafruit.com/product/3630) Attaching NeoPixel strips to your costume can be a struggle as the flexible PCBs can crack when bent too much. So how to add little dots of color? Use these stranded NeoPixel dots! They're very small, so they're easy to embed into any structure, costume, or wearable. Each dot is... In Stock [Buy Now](https://www.adafruit.com/product/3630) [Related Guides to the Product](https://learn.adafruit.com/products/3630/guides) ![Adafruit NeoPixel LED Dots Strand - 20 LEDs at 2 inch Pitch](https://cdn-shop.adafruit.com/640x480/3630-02.jpg) ### Adafruit NeoPixel LED Dots Strand - 20 LED 4" Pitch [Adafruit NeoPixel LED Dots Strand - 20 LED 4" Pitch](https://www.adafruit.com/product/3631) Attaching NeoPixel strips to your costume can be a struggle as the flexible PCBs can crack when bent too much. So how to add little dots of color? Use these stranded NeoPixel dots! They're very small, so they're easy to embed into any structure, costume, or wearable. Each dot is... In Stock [Buy Now](https://www.adafruit.com/product/3631) [Related Guides to the Product](https://learn.adafruit.com/products/3631/guides) ![Adafruit NeoPixel LED Dots Strand - 20 LEDs at 4 inch Pitch](https://cdn-shop.adafruit.com/640x480/3631-04.jpg) ## Battery Power I'm using a 2000mAh lithium battery to power my project. This battery fits perfectly inside a GoPro Hero 4 case and will power lots of lights for several hours.  Get a second or third one to keep on-hand if you want to run your costume all night. ### Part: Battery quantity: 2 Lithium Ion Battery - 3.7V 2000mAh [Battery](https://www.adafruit.com/product/2011) ### Part: Battery Connector quantity: 1 JST PH 2-Pin Cable – Male Header 200mm [Battery Connector](https://www.adafruit.com/product/3814) ### Part: Battery Charger quantity: 1 Adafruit Micro Lipo - USB LiIon/LiPoly charger - v1 [Battery Charger](https://www.adafruit.com/product/1304) Danger: If your project is meant to be worn by kids, or if you plan to get it soaking wet, you may want to consider using AAA batteries instead. Lithium batteries can be dangerous things. If they get punctured and wet, they can catch fire or explode. I'm an adult, I've been making LED costumes for years, and I know the risks, so I'm using a less-safe option so that I can use a smaller enclosure box.  ### Part: AAA Battery Box quantity: 1 3 x AAA Battery Holder with On/Off Switch and 2-Pin JST [AAA Battery Box](https://www.adafruit.com/product/727) ## Enclosure To keep our microcontroller and battery safe from the elements, we need a good dust-proof enclosure. I'm using a repurposed [GoPro Hero 4 camera case](https://www.amazon.com/Suptig-Replacement-Waterproof-Protective-Underwater/dp/B01G77CQDS/). It's rated IP68 (waterproof down to 147 feet).  In order to get the power, ground, and data wires through the case I'll use a cable gland. These are purpose-made to create waterproof wire pass-throughs.  I'll also use a waterproof connector to attach the controller box to the costume. ![projects_10_case_drilled.jpeg](https://cdn-learn.adafruit.com/assets/assets/000/116/170/medium640/projects_10_case_drilled.jpeg?1666716079) ### Part: Cable Gland quantity: 1 Cable Gland PG-7 size - 0.118" to 0.169" Cable Diameter - PG-7 [Cable Gland](https://www.adafruit.com/product/762) ### Part: Waterproof Connector quantity: 1 Waterproof Polarized 4-Wire Cable Set [Waterproof Connector](https://www.adafruit.com/product/744) ## Sealing Wire Connections We have sturdy light strands, but they still need to connect to our microcontroller and to each other. The solder joints tend to be the weak point in most projects. Here are some products that will help keep your joints rock-solid. ### Part: Silicone Stranded Wire quantity: 3 Silicone Cover Stranded-Core Wire - 2m 26AWG [Silicone Stranded Wire](https://www.adafruit.com/product/1877) ### Part: Standard Heat Shrink quantity: 1 Heat Shrink Tubing in various sizes [Standard Heat Shrink](https://www.adafruit.com/product/344) ### Part: Clear Heat Shrink quantity: 1 3/4" Clear Heat Shrink Tubing [Clear Heat Shrink](https://www.adafruit.com/product/1020) ### Part: Ribbon Cable Wire quantity: 1 Silicone Cover Stranded-Core Ribbon Cable - 4 Wires 1 Meter Long - 26AWG Black [Ribbon Cable Wire](https://www.adafruit.com/product/3892) ## Tools & Accessories - Heat Gun - Hot Glue Gun - Soldering iron & accessories - Cable ties - Power drill with a 15/32 (12mm) drill bit for the cable gland install ![LED Mermaid Glimmer](https://cdn-learn.adafruit.com/assets/assets/000/116/352/medium800/projects_glimmer_tank-6.jpg?1667150501) - [Next Page](https://learn.adafruit.com/light-up-costumes-in-harsh-environments/design-layout.md) ## Featured Products ### Adafruit QT Py ESP32 Pico - WiFi Dev Board with STEMMA QT [Adafruit QT Py ESP32 Pico - WiFi Dev Board with STEMMA QT](https://www.adafruit.com/product/5395) This dev board is like when you're watching a super-hero movie and the protagonist shows up in a totally amazing costume in the third act and you're like 'OMG! That's the hero and they're here to kick some serious butt!" but in this case its a... Out of Stock [Buy Now](https://www.adafruit.com/product/5395) [Related Guides to the Product](https://learn.adafruit.com/products/5395/guides) ### USB Type A to Type C Cable - approx 1 meter / 3 ft long [USB Type A to Type C Cable - approx 1 meter / 3 ft long](https://www.adafruit.com/product/4474) As technology changes and adapts, so does Adafruit. This   **USB Type A to Type C** cable will help you with the transition to USB C, even if you're still totin' around a USB Type A hub, computer or laptop. USB C is the latest industry-standard connector for... In Stock [Buy Now](https://www.adafruit.com/product/4474) [Related Guides to the Product](https://learn.adafruit.com/products/4474/guides) ### Adafruit NeoPixel LED Dots Strand - 20 LEDs at 2" Pitch [Adafruit NeoPixel LED Dots Strand - 20 LEDs at 2" Pitch](https://www.adafruit.com/product/3630) Attaching NeoPixel strips to your costume can be a struggle as the flexible PCBs can crack when bent too much. So how to add little dots of color? Use these stranded NeoPixel dots! They're very small, so they're easy to embed into any structure, costume, or wearable. Each dot is... In Stock [Buy Now](https://www.adafruit.com/product/3630) [Related Guides to the Product](https://learn.adafruit.com/products/3630/guides) ### Adafruit NeoPixel LED Dots Strand - 20 LED 4" Pitch [Adafruit NeoPixel LED Dots Strand - 20 LED 4" Pitch](https://www.adafruit.com/product/3631) Attaching NeoPixel strips to your costume can be a struggle as the flexible PCBs can crack when bent too much. So how to add little dots of color? Use these stranded NeoPixel dots! They're very small, so they're easy to embed into any structure, costume, or wearable. Each dot is... In Stock [Buy Now](https://www.adafruit.com/product/3631) [Related Guides to the Product](https://learn.adafruit.com/products/3631/guides) ### Lithium Ion Battery - 3.7V 2000mAh [Lithium Ion Battery - 3.7V 2000mAh](https://www.adafruit.com/product/2011) Lithium-ion polymer (also known as 'lipo' or 'lipoly') batteries are thin, light, and powerful. The output ranges from 4.2V when completely charged to 3.7V. This battery has a capacity of 2000mAh. If you need a larger (or smaller!) battery,  In Stock [Buy Now](https://www.adafruit.com/product/2011) [Related Guides to the Product](https://learn.adafruit.com/products/2011/guides) ### JST PH 2-Pin Cable – Male Header 200mm [JST PH 2-Pin Cable – Male Header 200mm](https://www.adafruit.com/product/3814) For a really long time we assumed that the JST PH didn't have a free-hanging male header version. But then we found this **JST-PH 2-pin Male Cable,** and we were like, _this is perfect!_ It's not a genuine JST connector, but it's 100%... In Stock [Buy Now](https://www.adafruit.com/product/3814) [Related Guides to the Product](https://learn.adafruit.com/products/3814/guides) ### Adafruit Micro Lipo - USB LiIon/LiPoly charger [Adafruit Micro Lipo - USB LiIon/LiPoly charger](https://www.adafruit.com/product/1304) Oh so adorable, this is the tiniest little lipo charger, so handy you can keep it any project box! Its also easy to use. Simply plug in the gold plated contacts into any USB port and a 3.7V/4.2V lithium polymer or lithium ion rechargeable battery into the JST plug on the other end. There are... In Stock [Buy Now](https://www.adafruit.com/product/1304) [Related Guides to the Product](https://learn.adafruit.com/products/1304/guides) ### Cable Gland PG-7 size - 0.118" to 0.169" Cable Diameter [Cable Gland PG-7 size - 0.118" to 0.169" Cable Diameter](https://www.adafruit.com/product/762) We have some great [waterproof and weather-proof](https://www.adafruit.com/?q=waterproof&) items in the adafruit shop, but once you have a project built, you'll want to enclose it. But how to keep an enclosure weather/waterproof while still attaching cables for power, data... In Stock [Buy Now](https://www.adafruit.com/product/762) [Related Guides to the Product](https://learn.adafruit.com/products/762/guides) ## Related Guides - [Adafruit QT Py ESP32 Pico](https://learn.adafruit.com/adafruit-qt-py-esp32-pico.md) - [Adafruit NeoPixel Driver BFF](https://learn.adafruit.com/adafruit-neopixel-driver-bff.md) - [Sound Reactive LED Top Hat](https://learn.adafruit.com/sound-reactive-led-top-hat.md) - [Flora+NeoPixel LED Skateboard Upgrade](https://learn.adafruit.com/flora-neopixel-led-skateboard-upgrade.md) - [Glowing Skullcandy Headphones Mod](https://learn.adafruit.com/glowing-skullcandy-headphones-mod.md) - [Make It Glow - Your First NeoPixel Project](https://learn.adafruit.com/make-it-glow-your-first-neopixel-project.md) - [NeoPixel Remote: IR Control with WLED](https://learn.adafruit.com/neopixel-remote-ir-control-with-wled.md) - [CircuitPython LED Animations](https://learn.adafruit.com/circuitpython-led-animations.md) - [Cyberpunk Santa Eye](https://learn.adafruit.com/cyberpunk-santa-eye.md) - [Video Nub Shank: ESP32 QT Py Composite Video Injector](https://learn.adafruit.com/video-nub-shank-esp32-qt-py-composite-video-injector.md) - [GEMMA Hoop Earrings](https://learn.adafruit.com/gemma-hoop-earrings.md) - [LIGHTSHIP: LED Animation over WiFi](https://learn.adafruit.com/lightship-led-animation-over-wifi.md) - [Gemma-Powered NeoPixel LED Sound Reactive Drums](https://learn.adafruit.com/gemma-powered-neopixel-led-sound-reactive-drums.md) - [3D Printed LED Buckle](https://learn.adafruit.com/3d-printed-led-buckle.md) - [CPX Glowing Disembodied Hand](https://learn.adafruit.com/cpx-glowing-disembodied-hand.md) - [Circuit Playground Express Rocket Lamp](https://learn.adafruit.com/cpx-rocket-lamp.md) - [Color-sensor Driven NeoPixel Dress](https://learn.adafruit.com/color-sensor-driven-neopixel-dress.md)