This guide will show you step-by-step instructions with pictures on how to make your own LED headband. These instructions are designed to help you understand how circuits work and how to sew.
Time: 25 - 45 minutes
STEP 1: Gather Materials
STEP 2: Cut the Felt
To cut the felt long enough, you have to cut it diagonal on the sheet. Cut one Diagonal line. Line up the triangle piece (corner piece you cut off) with the other corner. Cut along the outline of the triangle. Your final piece of felt should be a straight line with the ends being pointy and a 2 inch width.
STEP 3: Layout the Parts
You should have all the negative ends of the LED lights and the battery holder all facing one way (in these pictures, the negative ends are facing up). This leads to all the positive ends facing the opposite direction of the negatives (facing down in the picture). The battery holder will be hidden when you are wearing the headband so it will be on the bottom. The LED lights will be on top of the headband for people to see the lights shining!
STEP 4: Cut Thread, Thread Needle, and Knot Thread
Cut conductive thread a reasonable length in order to sew the LEDs and battery holder on the positive or negative sides. Thread the needle with the conductive thread. Ask for help, if needed. Tie a knot in the thread on the opposite end of the needle (knot three times). The purpose of tying a knot is to stop the thread from pulling all the way out of the material.
STEP 5: Sew the Battery Holder on the Positive Side
You are going to connect all the positive ends together first. Use conductive thread! The battery holder will go on the bottom of the headband so no one can see it. Opposite of the LEDs. Pull the needle from the bottom of the headband through the positive battery holder hole. Loop three times. Sew towards the LED light with the same thread.
STEP 6: Sew the LED Lights on the Positive Ends
All positive ends of the LED lights should be facing the same direction as the positive battery holder side. Using the same thread as step 5, sew through the hole of the first LED light and loop three times. Move on to the next LED light and loop three times. Depending on how many you use, you may have to keep going. Tie a knot (knot three times) and cut the thread.
STEP 7: Sew the Battery Holder on the Negative End
Repeating step 5 for the negative ends. You now are going to connect all the negative ends together. All instructions are repeated below from step 5. Thread the needle with new conductive thread. Make a knot on the opposite side of the needle in the thread (knot three times). Pull the needle from the bottom of the headband through the negative battery holder hole. Loop three times. Now, sew towards the negative LED lights with the same thread.
STEP 8: Sew the LED Lights on the Negative Ends
Repeating step 6 for the negative ends. You now are going to connect all the negative ends together. All instructions are repeated below from step 6. All negative ends of the LED lights should be facing the same direction as the negative battery holder side. Since you are connecting all the negatives, you should be using the same conductive thread. First, sew through the hole of the firs LED light and loop three times. Move on to the next LED light and loop three times. Depending on how many you use, you have to keep going. Tie a knot (knot three times) and cut the thread.
STEP 9: Test
Insert the battery in the battery holder and test the LEDs. Your LEDs should all light up. If not, figure out why.
Do you have a short circuit? Do you have a backwards LED?
STEP 10: Cover the Battery
No one wants a battery touching their hair! Since the battery will be on the unseeable side of the headband, where your hair is, the battery will be touching your hair. So, I advise you to cover the battery with felt to protect your hair. Cut a piece of felt big enough to cover the battery holder and to sew the material around it (around 2 1/2 inches). Using regular thread, thread the needle and make a knot on the opposite side of the needle in the thread (knot three times). Sew it on each side, tie a knot (knot three times), and cut the thread!
STEP 11: Decorate
Before completing the headband with elastic, you should decorate the headband first. This will make it easier to sew. Use regular thread!
STEP 12: Measure Elastic
In order for your headband to stay in your hair, you have to measure it around your head and cut the elastic accordingly. You do not want it too loose or too tight.
STEP 13: Add Elastic Backing
Using regular thread thread the needle and make a knot on the opposite side of the needle in the thread (knot three times). Start attaching the elastic by pulling the needle through the bottom of the headband. Sew towards the other end of the elastic. I suggest sewing back to where you started sewing the elastic to strengthen the seam. Do the same for the other side of headband. Tie a knot (knot three times) and cut the thread.