Light-Up Pyramids

Designed a scalable hands-on activity for Virginia Tech engineering recruitment events. Interactive LED pyramids built by prospective students (elementary through high school) during campus visits—teaching soldering, circuits, and manufacturing processes while creating a take-home keepsake.

Goal: Make engineering tangible and exciting for middle and high school students through immediate, visible results.

Manufacturing Constraints:

• Producible in quantities of 50+ per event

• Assemblable by students aged 10-18 in 30-45 minutes

• Safe for supervised youth assembly

• Cost-effective at scale (<$5 per unit)

• Durable enough to survive transport home

Educational Goals:

• Introduce basic circuits and LEDs

• Demonstrate multiple manufacturing methods

• Require soldering (skill development)

• Show design-to-product workflow

• Inspire interest in engineering

Multi-Process Approach:

• 3D Printing:

• Custom angled panel holders

• Modular design for easy assembly

• Laser Cutting:

  • 3mm plywood pyramid panels (rapid production)

  • Precise dimensional tolerance

  • Clean edges (no post-processing)

  • Multiple units per sheet (material efficiency)

• Electronics:

  • LED circuits (students solder connections)

  • Safety considerations (low voltage, no exposed contacts)

Why This Mix?

To demonstrate to students different engineering tools.

3D printing: Complex geometry

Laser cutting: Flat precision parts, speed

Soldering: Assembly and connection

Design: Planning for all three

Efficiency Through Design:

• Batch manufacturing workflow

• Standardized component kits

• Pre-cut and pre-printed parts

• Assembly instructions optimized for young builders

• Station-based assembly (soldering, assembly, testing)

Results:

• 500+ units produced over 10 events

• 30-45 minute assembly time per student

• High success rate (>95% functional builds)

• Minimal material waste through optimized layouts

Student Experience:

• Receive kit with all components

• Learn soldering basics (supervised)

• Assemble circuit and housing

• Test functionality

• Take-home working project

Skills Introduced:

• Soldering technique

• Circuit basics (polarity, connections)

• Following assembly instructions

• Problem-solving (troubleshooting non-working circuits)

• Manufacturing process awareness

Feedback:

Students gained hands-on experience with engineering tools, many commenting that it was their first time seeing 3D printing/laser cutting in action. Several reported choosing engineering programs based on recruitment event experiences.

Challenges Solved:

v1 Issues:

• Pieces larger than needed required longer print times

• Wire routing unclear in instructions

• Poor solder joints for LED to USB power.

v2 Improvements:

• Smaller 3D printed parts for assembly, reducing material and print time.

• Simplified instruction graphics

• Soldering jig to ensure all solder joints are the same.

Production Optimization:

• Reduced laser cutting time by 40% through nesting optimization

• Streamlined 3D print orientation for strength and speed

• Standardized component sourcing for bulk pricing

Quantitative:

• 500+ units built

• 10+ recruitment events

• 500+ students engaged directly

• Estimated reach: 2,000+ (students + families)

Qualitative:

• Positive feedback from students and parents

• Requests from other departments to replicate model

• Students returned to show working pyramids at later visits

• Demonstrated effective blend of manufacturing methods