Building a SHADOW BOX WITH LED LIGHTS using the ProEDGE System

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1 Building a SHADOW BOX WITH LED LIGHTS using the ProEDGE System OBJECTIVE: Fabricate a Shadow Box frame with LED Lights by utilizing our 13/16 wideside ProEDGE hi-tech molding. This particular size molding, when used with 3/16 foamcore, creates a false cavity for the LED Light battery pack, micro switch and harness to be hidden from sight. The LED Lights alternate off and on, creating a wig/wag effect, to draw attention to your graphic. In the example shown below, we are using an image that has been mounted to 3/16 foamcore and laminated on both sides, and framed with ProEDGE 13/16 polished black hi-tech molding. Frontside Backside Finished 3-Sided Display

2 STEP #1 Once you have your image mounted to 3/16 foamcore, you need to punch a small pilot hole in the very center of each desired location for the lights. These will serve as a guide when creating the larger holes in Step #2. In our example, the desired result is to place the LED lights in the center of the Wizardʼs eye, in order to create a special visual effect. Therefore, the small holes will be located in the center of the wizardʼs eyes. (Illustration A) To make your pilot hole you may use a needle, extended paper clip, or weeding tool as shown below. Make sure that you push the pin into the foamcore straight and all the way through to the other side. (Illustration A-1) Illustration A Illustration A-1

3 STEP #2 After your small pilot holes are created from the frontside of your mounted graphic, flip your image over to the backside. Use your LED punch tool (included with LED KIT) and center the tip over one of the small holes. (Illustration B) Take a hammer and tap the end until you have punched through to the front side. Repeat as needed for each hole required. We have now produced a larger hole in each eye of the wizard to insert the LED light into. (Illustration B-1) Illustration B Illustration B-1

4 STEP #3 Once all the holes are punched, it is time to frame your foamcore with 13/16 ProEDGE hi-tech molding. (Illustration C) Fabricating the mitered corners is accomplished by using your ProEDGE fastframer. If there is a protective mask on your molding, we recommend leaving it on until you are ready to display your framed image. This will prevent fingerprints and scratches which can occur during production. Insert your metal hanging brackets before welding the hi-tech molding into place. (Illustration C-1) Lift up the inside lip of your molding and push in your bracket until it seats itself under the molding. Illustration C Illustration C-1

5 STEP #4 When the welding glue has cured (about 1 hour later) you may install the LED Lights. In this example, we will be using a 2-light LED kit, however, ProEDGE has a 5-light kit available as well. Our sample, a 2-light LED, comes with 2 lights, a AA battery holder (batteries not included), and a printed circuit board micro switch. Notice that each piece of the LED contains an adhesive backed piece of foam on the backside. Each piece of foam has a protective sheet of paper that will need to be removed BEFORE placing that piece on the foamboard. (Illustration D) The LED light kit after installing onto the foamcore. (Illustration D-1) Illustration D Illustration D-1

6 STEP #5 The backside of each light is numbered, revealing the directional flow of the blinking light pattern. (Illustration E) This is especially important on our LED 5-light kit, as the flashing LED lights will start with #1 and end with #5. The 2-light system will produce a wig/wag pattern, which alternates back and forth between the two lights. Illustration E

7 STEP #6 In order to conceal all of your wires, it is helpful to organize the loose wires and secure them in place with a small strip of masking tape. Add the hanging wire onto your hanging brackets and place two AA batteries in the battery holder to complete the installation of your LED 2-light kit. (Illustration F) Illustration F

8 Now your Shadow Box image with LED Lights is complete. Activate the LED lights by depressing the microswitch located on the back, and you will have created an eye-catching display! Before placing your completed image on the wall, be sure to remove the clear protective film from the hi-tech molding. LED Lights have many uses, including point of purchase displays, photographs, and even as bullet points on interior signage. You are only limited by your own imagination!