Ideas for punching round holes in front panel paper for LEDs? - Page 1
Forum section: electronics / beginners

author: killingtime
author_rank: Regular Contributor
timestamp: June 27, 2023, 11:25:03 am
content: Hi,I'll be printing an equipment box facia for a project using standard printer paper. I think this is how most DIYers make one off facias for their projects. The paper will then be glued onto a 3D printed back with all the holes in place.I need some 5mm LEDs to poke through the front. Any idea how to go about making neat 5-6mm holes in paper?Cutting manually always makes raggedy mess. A paper hole punch can't get more than 10mm in from the edge. Just wondered what other people are doing.Like the image below.Thanks.

author: Ian.M
author_rank: Super Contributor
timestamp: June 27, 2023, 11:48:30 am
content: Before fancy punch pliers there were manual hole punches - put the work on a resilient backing block, line up the hollow punch and strike it with a hammer!This sethttps://www.amazon.co.uk/Amtech-H1700-Hollow-Punch-6-Piece/dp/B005S0DN1K/(3mm-8mm) looks like it will do the job. You'll also need a thick HDPE chopping board a hammer, and possibly a large paperclip to push out any chads that get stuck in the punch.

author: beanflying
author_rank: Super Contributor
timestamp: June 27, 2023, 12:01:45 pm
content: This is why you NEED to add a proper Laser Cutter to your Tool CollectionLight Card Targets, engraved and cut.Manual punches for paper or even softer plastics still work well too.

author: AndyBeez
author_rank: Frequent Contributor
timestamp: June 27, 2023, 12:19:05 pm
content: For paper, mount the paper sheet first and then use the solid hole from the back as a cutting guide for a sharp knife.I've always 'cheated' and mounted my LED's using panel mount bezels - so if I mangle the hole then it still looks really neat. Given the pro look of your project, bezels (chrome, black plastic, clear plastic or coloured) might be more "wow" than just a nice hole in paper.Thinks, could you laminate the paper to give it a gloss finish?

author: rdl
author_rank: Super Contributor
timestamp: June 27, 2023, 12:32:00 pm
content: I would definitely go for the bezels (snap in holders). Black would look good. Be careful to get ones that are correct for the panel thickness. If they're a bit loose or wiggly, a dab of hot glue or similar will lock them down. A couple of coats of something like Krylon Clear on the paper is a good idea.

author: tszaboo
author_rank: Super Contributor
timestamp: June 27, 2023, 12:39:27 pm
content: You could order PCBs with the req. text and holes and whatnot and use that as enclosure front panel.Otherwise if you really want paper, then the modeller community has a great collection of techniques on how to do this.

author: Psi
author_rank: Super Contributor
timestamp: June 27, 2023, 12:40:25 pm
content: Probably your best bet for cutting clean holes in paper is one of those sewing tools you use to make holes in belts.The kind you want are just different sizes of circles, some others include odd shape holes but that isnt of much use for your application.Or, just make a PCB front panelholes and 2 color text is free (copper/ENIG/HASL and silkscreen).Black PCB with ENIG and white text looks cool.

author: rstofer
author_rank: Super Contributor
timestamp: June 27, 2023, 01:06:06 pm
content: I preprinted the legends from a CAD file, sandwiched the sheet between 2 pieces of acrylic and drilled through the stackup with a CNC machine. Even the big hole for the meter body was cut on CNC.I wanted the analog computer so I bought the mill and converted it to CNC for this specific project. It has come in quite handy for other projects over the years,https://www.grizzly.com/products/grizzly-7-x-27-1-hp-mill-drill-with-stand/g0704CAD is the best way to get the holes in the right place.

author: theHWcave
author_rank: Regular Contributor
timestamp: June 27, 2023, 01:06:26 pm
content: I use 3 methods depending on the size of hole and the distance from the edge. Its all in this old YouTube video I madehttps://youtu.be/6D1oOXUbIhLately I abandoned the "foil" to cover the paper and use a lamination instead, but the hole punching has not changed.

author: nali
author_rank: Frequent Contributor
timestamp: June 27, 2023, 01:18:17 pm
content: I go the PCB panel route nowadays, but for DIYing I used to drill holes smaller than the LED e.g. 2mm dia then mount the LED behind shining through the hole. Looks a LOT neater.For panel legends I used projector transparency (OHP) film, print in reverse then use spray adhesive to glue to the panel with the ink/toner on the inside against the panel. The only real downside is that OHP is fairly soft so scuffs easily, although I suppose you could add a layer of varnish.

author: Terry Bites
author_rank: Super Contributor
timestamp: June 27, 2023, 01:47:04 pm
content: A decent leather punch works, not the nasty rotary ones, the real thing. A light tap with a bit of wood behind works well.https://www.amazon.co.uk/sourcingmap%C2%AE-Leather-Gasket-Strap-Hollow/dp/B01MUB6KIA/ref=sr_1_5?crid=1BB4ZCNYD5PIK&keywords=leather+punch+5mm&qid=1687873226&sprefix=leather+punch+5mm%2Caps%2C90&sr=8-5.BTW. You sharpen them up by sticking them in adrill press and holding a band of emery paper against the outside. Then stick a cone of emery up the inside. Repeat until sharp.

author: jmelson
author_rank: Super Contributor
timestamp: June 27, 2023, 02:49:13 pm
content: I used to do this with a product that was a double-sided sticky vinyl with a printed acetate overlay. The printing was on the back of the acetate, it was then glued to the vinyl, and the vinyl then was applied to the machined aluminum panel while sitting on a light table so alignment could be done. Then, I used a new X-acto blade to cut all the holes. Basically, the X-acto blade formed one edge of a scissors and the aluminum was the other edge. It made truly perfect cutouts for connectors, pots and switches. I left the LEDs behind the vinyl and they just shone through the white vinyl, acting as a diffuser. Looked pretty professional. See :http://pico-systems.com/shapdisc.htmlI hope this answers your question.Jon

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: June 27, 2023, 02:51:25 pm
content: leather punchhttps://www.amazon.co.uk/Amtech-H1700-Hollow-Punch-6-Piece/dp/B005S0DN1K/ref=asc_df_B005S0DN1K/?tag=googshopuk-21&linkCode=df0&hvadid=208050023643&hvpos=&hvnetw=g&hvrand=9123439287306277487&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9044937&hvtargid=pla-421350505329&psc=1

author: David Hess
author_rank: Super Contributor
timestamp: June 27, 2023, 04:43:18 pm
content: One way I have done it, albeit with a real sheet metal hole punch, is to mount the printed paper to the sheet metal panel with spray adhesive, and then punch it. The close tolerances generated by the shearing metal allow the punch to cleanly cut the paper as well.I have also printed the markings reversed onto overhead projector sheets, and then mounted the sheets reversed, so the tough polyester protects the printing.

author: mariush
author_rank: Super Contributor
timestamp: June 27, 2023, 05:27:56 pm
content: It would probably be easier to have a nice big sticker printed with the stuff you want on the front transparent plexiglass/plastic rectangle, leaving some transparent squares for where the leds would be. Then you could have a small pcb with the leds glued to the plastic, maybe use some light pipes to route the light directly on those squares, instead of having the leds come out through the panel.Think how they do it with cheap switches and routers, where it's basically holes in plastic or metal and a sticker covering the holes...holes don't have to be round or precisely cut, because sticker covers the hole.With circuit board you could have light pipes inserted into holes into the circuit board and then glued on the back side. Or you could have surface mount leds that are designed to shine the opposite way (so you make a hole between the pads to have the led light go through that hole) and you could then have a sticker cover all the circuit board front or just have some transparent epoxy inside those holes before you solder the leds.edit :In this switch they have holes punched in the metal case, then sticker over the holes ... and the leds are on a tiny pcb with some black foam wth holes to prevent light bleed from other leds (see from around 10:00 ) :https://youtu.be/Lq_tOP-af9k?t=609

author: Doctorandus_P
author_rank: Super Contributor
timestamp: June 27, 2023, 06:00:40 pm
content: 1. Grind a V-groove in the back end of a drill.2. Use a drill press to drill a hole in metal or hard wood (with the front of the drill).3. Reverse the drill in the drill press, and use it as a punch.Paper may be to weak / fragile. It may help if you put something under it, such as for example a sheet of aluminium from a tin can.

author: james_s
author_rank: Super Contributor
timestamp: June 27, 2023, 07:18:19 pm
content: Quote from: Ian.M on June 27, 2023, 11:48:30 amThat's what I use, it works great. A scrap of wood works fine as a chopping board too.

author: killingtime
author_rank: Regular Contributor
timestamp: June 27, 2023, 08:07:21 pm
content: The manual hole punch sounds like a good idea. I'll order a set. I would love a laser cutter. It's the way forward for sure.Thanks for the replies.

author: notsob
author_rank: Frequent Contributor
timestamp: June 27, 2023, 08:13:06 pm
content: incorrect punches for this job mike, ones with the bevel on the inside edge are required to give a clean outer side cut

author: langwadt
author_rank: Super Contributor
timestamp: June 27, 2023, 08:17:48 pm
content: a cone shaped grinding stone poked through the paper and turned to abrade the paper along the hole edge might worksorta like the old trick of making bolt holes in gasket with a ballbearing and a hammer

author: voltsandjolts
author_rank: Unknown
timestamp: June 27, 2023, 08:18:11 pm
content: Quote from: killingtime on June 27, 2023, 11:25:03 amNah, print onto Avery heavy duty laser labels. Tough and durable.Also, worth learning Inkscape, combined with those Avery labels, you can make top notch panel labels.https://www.avery.co.uk/water-resistant/resistant-labels

author: jonovid
author_rank: Super Contributor
timestamp: June 27, 2023, 08:49:37 pm
content: 5-6mm holes in paper? use a 5mm support hole in a block of hard material like aluminum plate or sheet.poke a 1mm hole in the paper then . cut or dremel with a less then 3mm bit the hole using the support hole's lip as a . guide.my tip-try DIY Lithography Printingetching metal with electricity is a good way to add artwork to a aluminum panel.using image transfer with a laser printer and printed paper , acetone then engraving it by etching it.then paint the panel one color then use the engraving as a way to rub another color paint into the engravingsee youtube videos on this one. still looking for that video.i am still experimenting with this for my own projects so i have a professional look on any panel.

author: BeBuLamar
author_rank: Super Contributor
timestamp: June 27, 2023, 10:45:06 pm
content: I would burn the holes with a soldering iron.

author: SmallCog
author_rank: Frequent Contributor
timestamp: June 27, 2023, 10:49:35 pm
content: Quote from: voltsandjolts on June 27, 2023, 08:18:11 pmI use these waterproof labels as wellI draw the designs up in visio (because that's what we have)I just mark where the holes are going on the label then drill through the label and the box. Bezels hide any edges

author: Ian.M
author_rank: Super Contributor
timestamp: June 27, 2023, 11:08:13 pm
content: Quote from: notsob on June 27, 2023, 08:13:06 pmOn thin enough materials, sharp (and evenly ground) outside bevel punches cut a fairly clean hole. The problem with inside bevel punches is the chad tends to get stuck in them and if you let multiple chads build up, may need drilling to extract!

author: james_s
author_rank: Super Contributor
timestamp: June 28, 2023, 02:07:38 am
content: Quote from: voltsandjolts on June 27, 2023, 08:18:11 pmI print on standard paper then run it through my laminator, it works great and has the advantage of protecting the toner from abrasion. I wonder if laminating those labels would work too.

author: gbaddeley
author_rank: Regular Contributor
timestamp: June 28, 2023, 09:53:39 am
content: If you just glue paper or card to a front panel, over time it will be affected by humidity and may bulge, distort or delaminate.