For a laser cutting workshop that I am going to give, I had to design an easy project the kids can cut on the laser, put together and customize. If possible without glue. (because who has the patience for glue to dry)

My first idea was a button that can be pushed and turn on and pushed again to turn off, but that seemed a bit to complicated for the kids, so it ended up becoming a simple press button.

When you press the button, the led turns on and when you let it go, the led turns off.

The kids can customize the design on the top of the button themselves.

I will use 3 mm transparant plexiglass for the inner workings of the button and the kids can choose the color for the sides and top of the button.

Supplies

Materials:

3 mm Acrylic (plexiglass)
2025 button battery
5 mm led
Rubber band

Tools:

Laser cutter (or your local makerspace with a laser cutter)

Step 1: Design

I split the design in 4 parts, so I can cut it from different materials. An other benefit is that I can use smaller (scrap) pieces of acrylic. The smaller files also help if you want to cut it on a smaller laser cutter.

The first file cuts the battery, bottom part of the button.
The second file cuts the inside of the top of the button.
The third file cuts the sides of the button.
The fourth file cuts the top of the button and is the only part that the kids get to customize. It is also the only part with engravings.

The four files also divide the build into four steps.

I designed the tolerances for the kerf of my laser cutter (0.11 mm) so you might have to adjust the dimensions for the laser cutter you are using. (or come to my makerspace to make this button)

To make it easier for the kids to build the button, I added an Ikea style instruction. (and also because it was fun to make)

Step 2: The Battery Compartment

Put the two squares on top of each other with the battery compartment on top and the small square holes lined up.

Push the two parts with the recesses in the holes in the square parts. They are both the same and only will fit in one way.

Step 3: The Spring Mechanism

Pust het side pieces on the pins of the pieces with the recesses. Make sure to put the holes to the lower side.

Put the battery in with the negative site of the button cell on top.

Put a rubber band around the recesses. You can try how tight you should wind around the recesses.

This first part is finished now.

Step 4: Add a Led

Put a 5 mm led over the small piece (that looks like a small M). The short leg of the led should be 15 mm and the long (anode) should be just a little longer. Because the M-part is symmetrical, the polarity of the led doesn't matter.

Put the part with the led in the square piece. There is only one way it will fit.

Step 5: Inside of the Button

Put the two pieces (the bigger M) on top of the piece with the led. They are both the same and only fit one way.

Step 6: Add the Sides

The kids can choose the color of the sides themselves.

Put the four pieces on the sides of the square. The 3 mm rim of the 4 pieces should be on the side where the led is.

Step 7: Add the Top

The top of the button is all up to the kids to design.

You can just put it on top of the button, but a small blob of glue on every corner might make it just that little bit stronger.

When you design the top with an engraved part in the middle, the led will light up nice.

Step 8: Merge the Parts

When you put the top part of the button over the battery part, you have to make sure that the short leg of the led ends up on top of the battery and the long leg just beside it. So this time the polarity does matter.

Step 9: It Should Work

When you push the button, the light should go on and when you let go, it should turn off again.

All my buttons worked from the first try, but if yours doesn't, you might need to push the long leg a little bit closer to the acrylic and bend the last 3 mm a little bit outwards.

This project ended up very nice. It is a fun project to make on the laser cutter and when you separate out the four steps it is easy to make, even with younger kids (10+).

I prepared the transparent parts before they came, so we only have to cut the sides and top when the kids where here.