Maya Ellison
There are several ways to attach EL wire to plastic. One common method is to use glue, such as hot glue, E6000, or 3M Super Strength Adhesive. When using glue, it is important to ensure that the glue is compatible with plastics and will not block the visibility of the light from the wire. Another approach is to drill or melt holes in the plastic and thread the EL wire through, using a clear monofilament thread or fishing line to avoid blocking the light. Additionally, soldering can be used to attach EL wire to plastic, especially for more permanent installations. It is recommended to test the wire connections before attaching them to the plastic surface to ensure proper functionality.
| Characteristics | Values |
|---|---|
| Type of glue | Hot glue, E6000, 3M Super Strength Adhesive |
| Other methods | Safety pins, zip ties, clear tape, fishing line thread, fabric casing |
| Soldering | Solder the end of each piece of EL wire to a connector or double-conductor ribbon cable |
| Drilling | Drill holes in plastic to pass the wire in and out of the desired locations |
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What You'll Learn
Using hot glue
Hot glue is a great option to attach EL wire to plastic. It is a popular method used with materials such as cardboard, paper, plastic, etc., and does not damage their structural integrity. The hot glue will not damage the EL wire either, as it is covered in a clear plastic coating.
The main reason for using hot glue on EL wire is to provide a permanent but reversible bond between the wire and the surface you are trying to secure it to. The EL wire, unlike standard Light Emitting Diodes (LEDs), comes in varying lengths and is covered in PVC sheathing. This is great for protecting the inner cores of the wire and providing flexibility, but it can be challenging to form shapes and keep it in place.
To attach the EL wire to plastic, you can start by drilling holes in the plastic to thread the wire through from the back. The holes should be about the same size as the wire, just big enough to allow the wire to pass through without being too visible. Once you have the wire in place, hold it down and apply a drop or two of hot glue. You can use a Plasticator needle to apply the glue to the EL wire, and it will run down the sides. Hold the wire in place for 30-60 seconds while the glue melts the acrylic and creates a bond. Repeat this process for the next inch of wire, and so on.
While hot glue is a great option, it does have some disadvantages. One issue is that the glue could block or diffuse the light of the EL wire if too much is applied. When hot glue solidifies, it can turn opaque, so be careful not to cover the parts of the wire where light needs to shine through. Additionally, hot glue can get quite messy, and it may need to be reapplied periodically.
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Drilling holes in plastic
Choosing the Right Drill Bit
Select a drill bit specifically designed for drilling plastic. Spur-point drill bits, also known as dowel bits, are highly recommended for this purpose. They have a center point and two elevated spurs that help guide the bit straight, resulting in clean-sided holes and reducing the risk of cracks. Spur-point bits are available in sizes ranging from 3 to 10mm, ensuring versatility for different hole sizes.
If you are unable to find a spur-point drill bit, a standard Twist HSS (High-Speed Steel) drill bit can be a suitable alternative. These drill bits are commonly used for drilling acrylic or plastic and are often referred to as Jobber Drills. High-speed steel bits are versatile and can also be used for drilling wood, soft metals, and other materials.
For larger holes, you may consider using a step drill bit. This type of bit has a cone shape with increasing diameters, allowing you to create smooth-walled and straight holes. Step drill bits are excellent for avoiding splinters and cracks in the plastic. They are typically made from steel, cobalt, or carbide-tipped and are suitable for various materials, including plastic.
Avoid using spade bits or twist bits, as they can wander and cause uneven holes. If you must use a spade bit, create a dent at the center of the drilling point with a pointed tool first, and consider drilling a smaller pilot hole to guide the larger bit.
Drilling Technique
When drilling holes in plastic, it is crucial to use a slower drill speed. This prevents the generation of tremendous friction, which can cause the plastic to melt. Drilling at a slower speed also allows the chips to exit the hole immediately, reducing the risk of clogging. Remember, the larger the hole, the slower the drill speed should be.
Before drilling, clamp the plastic tightly to a stable surface. Use a spare piece of plywood or wood block underneath to support the drilling area and prevent tear-out. Painter's tape can also be applied to the intended drilling area to help protect the plastic surface and prevent cracking.
During the drilling process, apply a light but firm pressure to the drill. Use a lubricant, such as WD40, canola oil, or vegetable oil, to remove debris and reduce heat, especially when drilling deeper holes.
By following these instructions and choosing the right drill bit and drilling technique, you can successfully drill holes in plastic without damaging the material or compromising the quality of the holes.
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Soldering EL wire
Firstly, cut the wire to your desired length, leaving an extra inch for the wire connection. It is easy to make the wire shorter but hard to make it longer. Next, remove the outer coating. This is the hardest part of the process, so don't be discouraged if it takes a few tries to get it right. Use the 20 AWG or 18 AWG slot and strip off the PVC coating about half an inch (1 cm) from the end. You may find that heating the end of the EL wire with a heat gun softens the sheath, allowing you to pull it off easily while leaving the corona wires intact.
Now, tin the wire by heating it with a soldering iron and melting solder onto it. Cut the wire so that one side is about half an inch longer than the other, and tin the ends. EL is AC-powered, so you don't need to worry about polarity. Before you solder, get a piece of 1/8" heat shrink tubing and cut it to the same length as the middle wire piece (about half an inch). Pull the wire apart and slip the heat shrink tubing on, ensuring you have a quarter inch or more of clearance from the end of the wire, so the soldering iron doesn't prematurely shrink it.
Solder the wire to the middle conductor. If you're having problems, go back and tip both wires with plenty of solder so you can just heat them while touching. After 15 seconds, check that the solder connection has cooled, then slide the heat shrink tubing over the middle joint.
Then, solder the other wire to the copper tape. Slide a 1" piece of 1/4" heatshrink from the other end of the EL wire. Use your heat gun again to shrink the heatshrink over the whole assembly to protect it.
It is important to note that if you are soldering EL wire projects, you may find that when you have soldered everything and try to turn it on, it won't light up. Sometimes, when EL wire is cut, the tiny wires inside can cross over to the centre wire, creating a tiny short circuit. In this case, simply snip off the very tip of the EL wire.
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Using fishing line thread
When attaching EL wire to plastic, one method is to use fishing line thread. This is a clear thread that is non-conductive and will not block the light from the EL wire.
Firstly, you will need to drill tiny holes in the plastic, just large enough to thread the fishing line through. You can then sew the EL wire to the plastic using a needle and fishing line thread. It is recommended to use diagonal stitches, with a stitch every inch for straight lines, and closer stitches for sewing curves. When sewing, make sure the stitches are not too long, with a recommended length of 0.5" to 1.0" to prevent the EL wire from snagging or becoming loose. You can also tie an extra knot in the fishing line every 5-6 inches to prevent breaks and keep the EL wire in place.
If you are attaching EL wire to clothing, you can sew the wire to the fabric, ensuring the stitches are close together to hold the wire in the proper shape. You can also make a casing or channel with sheer fabric and slide the EL wire through, sewing it to the seams of the garment.
Another method is to use glue. You can mount the EL wire to a plastic surface using hot glue, E6000, or 3M Super Strength Adhesive. However, it is important to use glue that is suitable for use on plastics, as average craft store hot glue may not work.
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Attaching EL wire to fabric
When attaching EL wire to fabric, it's important to consider the type of fabric and the desired look of the final product. Some fabrics are better suited for EL wire installation than others. It is usually easier to work with fabric that has similar stiffness to the wire, and that does not stretch or flex too much where the wire will be installed. Recommended fabrics include leather, suede, vinyl, denim, thick cotton/polyester blends, velvet (non-stretch), faux fur, and quilted/padded jackets.
Before beginning, measure the total length of EL wire needed, taking into account hidden sections and adding 2-3 inches at the end of each piece for stripping and soldering. If you're not an experienced solderer, it's a good idea to order extra wire to practice with.
There are several methods for attaching EL wire to fabric, including sewing, gluing, and temporary methods. Sewing is a popular method, and it is recommended to use clear monofilament thread (fishing line) to avoid obscuring the light of the EL wire. When sewing, start at the wire's heat shrink and tie a knot around it, then continue making loops to hold the wire down. Sew with diagonal stitches along the wire, with stitches about 0.5" to 1" apart for straight lines, and closer together for curves. When sewing along a zipper, avoid looping the thread against it.
If the fabric is thick or difficult to sew, you can use topstitching as an anchor and tie extra knots in the fishing line every 5-6 inches to prevent the whole section from undoing if one part breaks. For some fabrics, a strong flexible glue may be a better option. Hot glue, E6000, and 3M Super Strength Adhesive are all suitable for attaching EL wire to plastic and may also work on fabric.
For a temporary attachment, you can weave the wire back and forth through holes in the fabric or use safety pins, zip ties, or clear tape. If you're attaching the wire to the arms of a garment, cut and assemble cardboard brackets to help hold the fabric taut while sewing.
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Frequently asked questions
You can attach EL wire to plastic using glue, such as hot glue, E6000, or 3M Super Strength Adhesive. Alternatively, you can drill or melt holes in the plastic and thread the EL wire through.
Hot glue is a popular choice for attaching EL wire to plastic. However, it may need to be reapplied periodically. Other types of glue that can be used include E6000 and 3M Super Strength Adhesive.
No, sewing is typically used for attaching EL wire to fabric or clothing. For plastic, gluing or drilling/melting holes and threading the wire are more common methods.
