Zócalo Neon Sign (From Babylon 5)

The Zócalo on Babylon 5 was a central meeting place in red sector where many characters would go to unwind, have drinks etc.  The ice blue neon sign recreated here featured in many many episodes in the background.  Through various forums Ive asked some who were on the show what the actual size was.  Supposedly the original was maybe about 6 feet long, meaning this one is about half scale.  Some screenshots show a red version of this sign that has a simpler rectangular background.  feel free to remix this as you wish and make that version as well.  It should be very easy to change the shape of the background.

https://babylon5.fandom.com/wiki/Zócalo

It has been designed to work with 6mm*12mm LED neon strips like these

https://www.amazon.com/dp/B08SHWJGW7?ref=cm_sw_r_apan_dp_3QKAX5JZMS86M5VG82J4_1&ref_=cm_sw_r_apan_dp_3QKAX5JZMS86M5VG82J4_1&social_share=cm_sw_r_apan_dp_3QKAX5JZMS86M5VG82J4_1&starsLeft=1&skipTwisterOG=1

The following videos are what I used to figure out how to do this and may be of some help when designing your own or wiring this sign up.

The sign has been split into 18 sections ( to make it printable on a prusa mini) joined with mortise and tenon joints with a 0.16mm tolerance.  Theres another folder with a cut into 10 sections and one cut into 8.

The tolerances should make the joints very strong and require little to no gluing.  Your printer may vary.  if the fit is too tight, a little sanding of the tenons should be all thats needed to get things to fit.  I have included g code files for the mini as well.  Files are labled relative to their position in an xyz grid.  It shouldnt be too hard to figure out how it is assembled.  I have included a screen shot of the LuBan cut as a guide.

here is the luban website if you want to cut up the big sign differently.

https://www.luban3d.com

Because the LEDs generate some heat you will want to print this in PETG or other heat tolerant material.

As designed, it should use about 11.5-12 feet of the LED strip so a single led strip should be more than enough.  You will also want the 5 amp power supply recommended in the amazon listing.

On the back are channels for wiring, and 4 screw keyhole pockets.  The idea is that you would hang this sign using studs spaces 16" apart and I've given you two pairs of screw pockets to help you place this where you like.  Wiring can be secured with a little hot glue here and there.    All parts should be printable with a minimum of support.  

This model probably cant be scaled down or up easily as this would of course  change the size of the channels and then the LED strips wouldn't fit anymore.  A desktop version using EL wire could probably be made using the sketches and other resources in the included fusion 360 file.

The model was done on the xz plane in fusion.  not sure why I did that but it does mean you will have to reorient the parts in the slicer, unless you use the gcode for the prusa mini

If you are cutting the main file in luban, remember that you need to make the tolerance value negative.  I found -0.16 results is a slightly lose fit that precisely aligns everything.  I set tolerances in my split files to 0.15.  For strength I strongly recommend using plastic weld staples on the back. To check fit I suggest printing out the test blocks included in the files below

Finally, you will quickly learn that the LED strips tend to change length depending on which way they bend.  The pcb strip doesn't stretch or squish like the rest of it which is silicone, and the leds are off to one side.  its best to put the LEDs aon teh inside of the curve facing out.  Always cut off a little longer than you need.  You can squish it in a little or make adjustments later.  you cant ever make a strip longer.

For soldering I found it best to attach the wires in the middle of a strip and cut away at whatever silicone might be in the way.  run the wires perpendicular to the strip so that they go straight down.  the red wire connects to the top contact, and teh black wire connects to the bottom contact.  All LEDs are polar and these are no different.  red means positive, and black means negative.

Use hot glue to attach the wires in the channels in the back

The original sign was silver/grey with some teal dry brushed on to it.