How to make a sewable Halloween LED badge - Free templates included

Easily add a touch of home-made to your Halloween costume this year with our sewable Halloween LED badges. Using our free to download laser cutter templates we're going to show you how to add a sewable PCB LED to a simple cut out. There is a choice of two files available, and for this example we have sewn a ghost, but the steps are the same for the witch.

Badges made at our Workshop at Derby Mini Maker Faire.

Learn how to:

• Create a simple sewable electronic circuit.
• Use an easy sew PCB LED in a circuit.

Level of difficulty:

• Beginner.

Parts list:

In order to create your sewable Halloween LED badge you will need:

• Neoprene foam or other similar laser cut compatible material.
• Your choice of colour easy sew PCB LED.
• Miniature coin cell holder and cell.
• Conductive thread.
• Large eye e-textile needle.
• Either: Laser cut template file (ghost or witch).
• Or: PDF printable template file (ghost or witch).

You will also need the following:

• Either: Access to a laser cutter.
• Or: Scissors and craft knife.
• Safety pin.

Step-by-step guide to making a sewable Halloween LED badge.

Step 1

Cut out your choice of witch or ghost using the dxf template.

Step 2

Thread your needle with conductive thread. If you have never threaded conductive thread before you might want to refer to our handy threading a needle with conductive thread guide.

You will notice on templates that we have made engraving positions for the positive and negative sides of the LED and coin cell holder. Place the coin cell holder the correct way round, with the negative sign on the holder lining up with the negative side on the template. Start your first stitch off. If you haven't sewn with conductive thread before you might want to see our guide on starting to sew. Make sure the connection points are sewn tightly four or five times to ensure a good electrical connection. Once the coin cell holder is in place, run the stitches up through the alternating holes to where the LED will sit. Attach the LED in the same way you did the coin cell holder, making sure that the negative side aligns with the negative engraving on the badge, and making sure you sew tightly four or five times to get a good electrical connection. Finish the stitch off, if needs be refer to our guide, and cut the ends of the thread close to the components so no long bits of lose thread are left.

Step 3

With a new piece of thread repeat the procedure on the positive side of the coin cell holder.

Sew through the alternating holes towards the LED as before.

Sew the positive side of the LED into place, as before making sure the connection is tight and well made.

Cut the ends of the thread off close to the components to avoid lose ends creating a short circuit.

Step 4

Insert the battery, positive side upwards.

Step 5

Check that your badge lights up. If the LED does not light refer to our fault finding section for tips on where you may have gone wrong.

Step 6

Insert the safety pin from the back of the badge, through the top hole.   Feed the safety pin down and and through the bottom hole.   Keep feeding the safety pin all the way round until it's all the way back round to the back of the badge, and pin on to your clothes.

Step 7

Find a suitable place to pose with your new badge, or alternatively find two willing workshop participants to do it for you!

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