- 5/9/2018 - Picked up Particle Photon dev board from mailbox.
- 5/15/2018 - Begin embedded code prototyping. Everything works quite reliably except for the home WiFi network, apparently.
- 5/16/2018 - Began working on cloud app and Particle webhook integration.
- 6/3/2018 - Assembled the prototype box.
- 6/5/2018 - Pushed testing code to repo. Just need to mount everything in the boss' doorway and then we're officially hardware complete!
- 6/12/2018 - Worked on getting Elastic Beanstalk to behave and actually run the web app.
Cut 6 pieces of cardboard to make a box. For my build I decided to cut the side pieces a little short so that a bit of light would shine out onto the wall once the box was mounted in place.
Print a template to use for the sign's text. Align it with the center of your front piece of cardboard, as you'll be using it as a guide for you sign's text.
Using a thumbtack or a nail, punch holes along the edge of your guide's letters. No need to punch all the way through the cardboard; we'll be connecting the dots later with a razor blade later.
Using a razor blade and a steady hand, connect the holes you punched earlier. Be extra careful on the curved spots as it's easy for the blade to catch and tear the cardboard in those areas.
After cutting out our letters, remove them. You don't need them anymore after this. (Optional: Save the center pieces for the A and O letters and attach them to our light filter later on for a more professional look.)
Assemble all of the box except for the back piece. We'll be attaching components to that in the next step and still need to install lights before we complete the box. For my build I used a hot glue gun for speed as I lack clamps to hold my pieces in shape otherwise.
Using a mixture of friction, glue/tape, and a bit of ingenuity... mount the electronics. For my build I cut two small holes for the ultrasonic sensor and then glued it into place. The Particle Photon's header pins were simply punched through the cardboard back and then connected to the ultrasonic sensor (and later the LEDs) via female jumper wires.
Install the LED strip. There are many ways to do this, but I opted to use the strip's own tendency to unwind against the inside of the box to keep it in place. I also left its 4-wire connector (V+, GND (Blue), GND (Red), GND (Green)) hanging outside of the box so that I could change which of the strip's LEDs were being powered down the line.
Lastly glue the back of the box onto the remaining sign enclosure. You're now hardware-complete!