DigiBox: Interactive LED Frame with WLED and ESP32-WROOM

Overview

Powered by an ESP32 microcontroller and the WLED firmware, this project combines 3D printing, electronics, and programming to create a stunning LED display. The frame features a sleek 3D-printed enclosure and can be controlled via a web interface, allowing you to choose from a variety of lighting effects and colors.

This project provides everything you need to build your own Digi Box, including 3D printing files, a detailed bill of materials (BOM), and assembly instructions. Whether you're a beginner or an experienced maker, the Digi Box is a fun and rewarding project to bring to life.

Controllable via website, Alexa and mobile app

Features

Customizable LED Effects: Uses WLED firmware for a wide range of lighting effects, controllable via a web interface.

ESP32-WROOM Powered: Reliable and versatile microcontroller for seamless LED control.

3D-Printed Enclosure: Includes STL & STEP files for the frame, housing, and all necessary parts.

Level Shifter Integration: Incorporates a 74AHCT125 to safely shift the ESP32's 3.3V signals to 5V for WS2812B LEDs.

Complete Documentation: Full bill of materials (BOM) and step-by-step assembly guide.

What You'll Need

Hardware:

• 1x ESP32-WROOM development board (e.g., ESP32 DevKit V1) with Wifi
• 1x WS2812B LED Matrix 16x16 (256 LEDs, adjustable based on frame size)
• 1x 74AHCT125 level shifter (for 3.3V to 5V signal conversion)
• 1x 5V power supply (e.g., 100W, depending on LED count)
• 5x resistor 10 kΩ
• 1x resistor 470 Ω
• 1x capacitor 1000µF
• 1x DC Power Jack & Plug Set
• 5x Push Button 8mm (self resetting)
• 1x 40x60mm self soldering DIY circuit board
• 1x 16-30 AWG cable set multicolor
• 1x 3,1m 12 AWG cable red/black for Power Supply
• 14x 3mm x 16mm metric screw
• 14x 3mm fused threat
• 1x 5mm x 20mm metric screw
• 1x 5mm nut metric
• 1x power cable (yes, you have to cut)
• 1x Foam Tape (to fix LED Matrix on Frame precise)

Tools:

• 3D printer
• filament spools
• build plate adhesion aids
• digital calipers
• sandpaper or file
• tweezers
• soldering iron
• solder
• desoldering pump or wick
• wire cutters
• wire strippers
• needle-nose pliers
• multimeter
• screwdriver set
• utility knife or craft knife
• helping hands tool
• computer or notebook
• usb cable
• fume extractor
• anti-static wrist strap
• ruler or measuring tape
• safety glasses

Software:

• WLED firmware (available at https://install.wled.me)
• A computer to flash the ESP32-WROOM

3D Print the Enclosure:

Print all provided STL & Step files (frame, housing, mounts etc.) using your preferred filament and color (e.g., PLA or PETG). Best result with PLA+. Make sure your print is absolutely accurate. If you're not sure, it's better to do test prints first and calibrate until the results are just right. Ensure proper bed adhesion and cooling for best results.

My print details:

Filament: Sunlu PLA+ Black, Sunlu PLA+ Blue, Sunlu PLA+ White
Nozzle Diameter: 0,4mm 
Layer: 0,2 mm
Nozzle Temperatur: 230 °C
Bed Temperatur first Layer: 70 °C
Bed Temperatur rest Layer: 50 °C
Chamber Temperatur: 35 °C

I print in this order: 

• Backplate / Sunlu PLA+ Black
• Frames / Sunlu PLA+ Black
• Corners / Sunlu PLA+ Black
• Side Slider / Sunlu PLA+ Black
• Front Window / Sunlu PLA+ White
• Front Lid Base / Sunlu PLA+ Black & Sunlu PLA+ Blue
• Stand / Sunlu PLA+ Blue

Soldering

You'll find all the details of the circuit diagram in the files. 

Flash the ESP32:

Use the WLED installer to flash the ESP32-WROOM.
Configure WLED with your Wi-Fi credentials and LED settings (e.g., number of LEDs, pin).
You will find all informations for wled here.

Test and Finalize:

Power on the Digi Box and connect to the WLED web interface via your browser.
Test different effects and adjust brightness as needed.
Secure all components in the 3D-printed enclosure.

Notes

If you want to be sure, you can first connect all the electrical components to a breadboard and then install WLED. This way you can test if everything is working.
I print all the parts and then check if they fit. Then I solder all the components to the board and attach the cables. Now I connect the ESP32-Wroom, then solder the buttons.
Important: Make sure that pixel 1 must be at the top left and pixel 256 must be at the bottom right. !!!
Once all the soldering is finished, I connect the ESP32-Wroom to my computer with a USB-C cable and visit https://install.wled.me. I follow the instructions; they automatically install WLED on the board (really well done). After installation, you enter the Wi-Fi connection. Now you visit your own DigiBox website.
You have to configure your LED matrix and other settings. 
Direct them to https://kno.wled.ge.
I've taken screenshots of all relevant settings in WLED. You can find them in the Settings.zip file.

Safety First: Follow all safety guidelines for 3D printing, soldering, and electrical assembly. Disconnect power when making changes to the circuit.

Customization: Modify LED count to suit your needs. The WLED firmware supports a wide range of configurations.

Support: If you encounter issues, check the WLED documentation or community forums for help.

License and Restrictions

• This project is shared under a restrictive license to protect the creator's intellectual property. 
  The following is expressly prohibited:
• Making any modifications or alterations to the model or its components.
• Republishing or redistributing the model, 3D printing files, firmware, or documentation.
• Using the model or its parts for commercial purposes, sale, or marketing.
• Distributing the 3D printing files, firmware, or project materials to third parties.
• Reverse engineering, decompiling, or modifying the model or firmware to analyze or replicate its functionality.
• Removing copyright or source attributions (e.g., creator's name or project link).
• Adapting the model for other platforms or purposes without explicit written permission.
• Using the model in public installations, exhibitions, or commercial settings without prior consent.
• Duplicating the model for mass production.
• You are permitted to download and assemble the Digi Box for personal, non-commercial use only, provided you adhere to these restrictions and give appropriate credit to the original creator.