To show off the panel, I built a delicious frame/case sandwich to hold the backlit panel, LED matrices, and the electronics and wiring in place.
The frame is made from acrylic and EVA foam, with a wood veneer on the front panel that is incredibly handsome, matching the wooden details of the Enterprise-D, and functional -- it holds the LCARS panel in place.
CAD Files
The parts were cut from 3mm acrylic, 6mm EVA foam, and 0.24" (24 mil) wood veneer using an Epilog Zing laser cutter. You can use the attached SVG files to cut your own framing pieces -- if you don't have access to a laser cutter there are online services available. Or, use the files as a printed template to guide using a bandsaw and drill!
Light Blocker
Use a layer of acrylic cut in a pattern that matches the graphics to avoid any light leakage when segments are turned off. This will help isolate the animation to the intended sections of the backlit graphic.
Front Frame
The front frame piece will hold the LCARS panel in place, along with the thin wood veneer placed on top of it.
Heat Set Threaded Inserts
Stack the front frame and then the blocker layers as shown, then insert the threaded inserts using a soldering iron (or specialized tool) as shown. Be sure to the the orientation of the panels correct so they will match the graphic!
A second bracket layer is laid over the first and then they are both screwed to the LED panels using M3 screws as shown.
Matrix Portal
Prep the Matrix Portal by soldering the E-line address jumper to pin 8 as shown here in the main guide.
Press the Matrix Portal into the IDC header as shown.
Custom Power Harness
Make a power harness for external power using the included power wiring. Cut the terminal connector ends off and screw the wires into the DC jack adapter
Re-use the black terminal wire end to connect ground to the Matrix Portal's negative (-) terminal screw post.
Power and Data
Plug the IDC ribbon cable into both panels to share data.
Plug in the power connectors to both panels.
Foam Stack
A stack of three 6mm EVA foam pieces will provide spacing for the front panels, and nestle the LED matrices in place.
Back Panels
Add the back foam spacer (this allows clearance for the power and data cables).
Then, place the back cover on, stack them onto the front panel (don't put the LCARS in yet) and screw these into place with the M4 x 40mm screws.
Veneer Prep
Cut the wood veneer out -- this type of veneer comes with the 3M adhesive backing already applied. I used the laser cutter to the the precise cut, and decided to wait until after cutting to apply stain and finish, since I wasn't eager to test the flammability of the stain and finish combo.
Give the wood a few coats of stain, followed by a spray varnish when dry. Be sure to work in a well ventilated place to avoid fumes.
Adhesive Prep
This step is optional -- if you want to avoid getting any adhesive on the backlit panel itself, you can score the peel-back paper in a 4mm offset as shown using tweezers, a compass, a set of calipers, etc.
Veneer Mounting
Place the LCARS into the front frame.
Carefully peel the adhesive backing and place the veneer onto the front panel as shown.
It can help to peel and work the veneer into place from bottom to top. Work carefully, as it can be difficult to remove the veneer once it has adhered to the acrylic.
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