KiCad

Summary

KiCad is an open-source PCB (printed circuit board) design software that Sean Hodgins used as the primary tool for creating complex circuit board layouts across multiple projects. Most notably, in "I Built the Craziest LED Mask", Sean used KiCad to design the intricate circuit board layouts for the LED Face Mask Project, transforming a 3D mask shape into functional LED panels containing 2,960 individual LEDs across multiple circuit boards. The software enabled him to handle the complex process of converting 3D geometry into flat panel designs and managing the massive repetitive task of placing hundreds of LED components.

Details

In "I Built the Craziest LED Mask", Sean Hodgins details the multi-step workflow that relied on KiCad for the PCB design phase. During his description of the design workflow, he outlined the sequence of operations: "flatten the parts create a panel import into keycap fix all the errors design the schematic import components copy paste copy paste copy paste." (Note: "keycap" appears to be a transcription error for "KiCad" in the audio.) This quote reveals both the technical complexity of working with KiCad on this project and the repetitive nature of the work—particularly the extensive copy-pasting required to place LEDs across the multiple panels.

The workflow begins with flattening the 3D mask parts and creating panels, which are then imported into KiCad. Once imported, the process involved fixing errors that arose during the import process, designing the electrical schematics that would control the LEDs, importing the necessary electronic components, and then executing the massive task of copying and pasting LED positions across the panels to achieve the final count of 2,960 LEDs.

The software served as the bridge between the 3D design work (using Wintercroft mask templates as a base) and the physical PCB manufacturing that would eventually be handled by PCBWay. KiCad's ability to handle complex, multi-panel designs with hundreds of repeated components made it the appropriate tool for a project of this scale and ambition.

In "GPS Has a Secret Job", Sean demonstrates KiCad's Interactive BOM (Bill of Materials) feature as a teaching aid during the PPS Watch Project assembly with Jeff Geerling. He displays the HTML file on a TV screen to help Jeff identify component locations, quantities, and proper orientation during the surface-mount soldering process. At timestamp 11:01, Sean explains: "So, in KiCad, there's a key bomb that builds a like HTML file for your board that lets you easily see where your components go."

Sean is particularly enthusiastic about the Interactive BOM's first-pin highlighting functionality, explaining to Jeff that it "just kind of tells you the orientation of the chips" — a crucial feature when working with surface-mount components where incorrect orientation can ruin a board.

Sean also showcases KiCad's integration with component suppliers, specifically Digi-Key, noting that when you export the BOM to Digi-Key, "it can populate that right into Digi-Key when you order it," streamlining the ordering process through automated label population. He emphasizes the importance of KiCad's PCB silkscreen labeling capabilities, expressing frustration with unlabeled boards: "I hate it when you look in there and it's like no labels anywhere. You got to do it if you're making your own boards." After successfully using the TV display method, Sean comments, "I'm definitely going to use it on this TV more often," suggesting this workflow has become a valuable part of his electronics assembly process.

History

I Built the Craziest LED Mask

KiCad was introduced as the PCB design software Sean Hodgins selected for creating the circuit board layouts for his LED mask panels. Sean described the workflow in his characteristic rapid-fire style, listing the steps: "flatten the parts create a panel import into keycap fix all the errors design the schematic import components copy paste copy paste copy paste." The emphasis on "copy paste" repeated multiple times highlights the scale of the repetitive work required—placing nearly 3,000 individual LED components across multiple panels was a significant undertaking within the software. The KiCad design phase came after the 3D modeling and flattening work, and before the physical manufacturing of the PCBs. It was the critical step that transformed the geometric concept of the mask into electrical schematics and board layouts that could actually be manufactured and assembled into a functioning LED display system.

GPS Has a Secret Job

KiCad appears as the design tool behind the PPS Watch Project PCB that Sean and Jeff Geerling are assembling. Sean uses the software's Interactive BOM (Bill of Materials) feature as a teaching aid, displaying the HTML file on a TV screen to help Jeff identify component locations, quantities, and proper orientation during the surface-mount soldering process. At timestamp 11:01, Sean explains how the feature works: "So, in KiCad, there's a key bomb that builds a like HTML file for your board that lets you easily see where your components go." The demonstration highlights how KiCad's features make electronics assembly more accessible, even for those new to surface-mount soldering like Jeff.