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INTRODUCING THE AMERICAN FLAG
LED SOLDERING KIT / LEARNING PROJECT

The STEMSuperPowersUSA Mission

To empower future innovators through high-quality, hands-on STEM kits that introduce essential skills in electronics, components, and assembly—making learning practical, engaging, and transformative.

(KIT- 1)

Electronics Assembly & Learning Project –

American LED Flag

Most Likely the First-Ever LED American Flag

Designed by a U.S. Electrical Engineer

Engineered for Learning. Built to Inspire. Proudly Illuminated.

The LED American Flag Electronics Assembly & Learning Project is the very first in a series of kits. My hope is that it will not only teach you essential assembly & soldering skills but also spark a deeper interest in the world of electronics.

The Inspiration Behind the LED American Flag Project

The concept of turning the iconic United States flag into a hands-on electronics project was born from a desire to create an engaging, educational experience. The flag’s design is strategically divided into 37 individual circuits, allowing for a structured and methodical assembly process. This division enhances learning by making it easier to independently test and troubleshoot each section, significantly improving the chances of completing a fully functional build.

This isn’t another imported novelty—it’s a one-of-a-kind electronics assembly and learning project, carefully crafted by a retired American electrical engineer to inspire hands-on learning and proudly illuminate the spirit of American ingenuity.

What Makes This Flag Different

Most LED flags on the market are generic, mass-produced overseas. There is currently no other LED American flag available that was designed by an American electrical engineer and developed for builders and learners. This is your opportunity to own a piece of that story and share it with pride.

Designed by an American Engineer

A modular electronics project with 37 testable circuits for structured learning
Powered by safe 24VDC external power supply.
Mixed technology – utilizes both through-hole and surface-mount components
Comes with a full instructional suite: build guide, circuit theory, BOM, and troubleshooting and repair tips

This isn’t just a flag—it’s a teaching tool, a showcase piece, and a tribute to the values that made it possible.

Section-by-Section Construction

The LED American Flag PCB features a unique design that allows for complete assembly all at once or step-by-step in 37 distinct sections, each containing 7 to 8 components. This modular approach lets you build the flag one section at a time, testing each for proper operation before moving on to the next. This ensures that your component assembly and soldering are correct, and everything works as expected before proceeding. If a section functions properly, you can confidently move on to the next, knowing you're on the right track. If a section doesn’t work, you only need to troubleshoot a small set of components, making it easier to identify and fix any issues before continuing. This approach creates a smoother and more rewarding learning experience.

This project is specifically crafted to reduce the learning curve, offering both a practical and educational experience that brings immediate satisfaction as you see your progress.

Why You’ll Love the LED American Flag Electronics Project

Build Your Own Glowing Flag Create a dazzling display of stars and stripes using both through-hole and surface-mount components. Feel the excitement of electronics assembly as you bring the American flag to life with your own hands.

A Challenging and Rewarding Experience The project features 266 components to practice your soldering and assembly skills, making it perfect for both beginners and seasoned enthusiasts. This project is designed to enhance your electronics abilities by offering diverse components and techniques in one build.

Flag PCB Specifications

PCB Dimensions – 300 mm x 180 mm
Design: 13 stripes, 50 white stars, maintaining the flag's standard proportions
LED layout: 50 white LEDs arranged as stars within the blue canton, alternating red and white stripes, with a blue LED perimeter forming the border of the canton
Total Components: 266 (228 through-hole, 38 SMT resistors)
Build Structure: 37 modular testable sections
Power Input: 24VDC (external power supply)
Display Options: Open-face enclosure (stand, wall-mount, or hangable)
Visibility: High-brightness LEDs visible over 100 yards

What’s Included in the Project

Custom PCBs – LED American Flag circuit boards, precision-fabricated
Parts List Provided – You must source your own components: LEDs, resistors, Shockley diode, wire, 24V connector, power supply.
Basic Instructions – Includes soldering guidance, circuit operation overview, and troubleshooting guide
Enclosures Sold Separately – Custom-fit housing available

Beyond Soldering: Versatility and Longevity

While the project is an excellent electronic learning and soldering practice tool, it’s also versatile and long-lasting:

Personal and educational use: Great for school projects, personal hobbies, or as a learning aid
Perfect gift: An ideal gift for DIY enthusiasts or anyone passionate about electronics and patriotism
A lasting ornament: Once assembled, it transforms into a beautiful, glowing ornament for your home, office, or business

Educational Value

Each segment of the flag is buildable and independently testable, which creates a guided, frustration-free learning experience. It’s ideal for:

Electronic hobbyists
Schools and STEM classrooms
Electronics workshops
Maker communities
Patriot-themed displays or tributes
Veterans' centers and civic organizations

With its extra-bright LEDs, this flag is visible from over 100 yards, making it a standout piece for any space. The LEDs have an impressive 50,000-hour lifespan, ensuring your project will last for years.

With spare components, you’re always prepared if something needs to be replaced. With the soldering knowledge you gain, and the extra components, you’ll be able to maintain your LED Flag for decades to come.

What Your Support Helps Fund

Hosting and maintenance of the project website
Design software and development tools
Prototyping
Ongoing improvements and new feature updates
STEM outreach and educator collaboration
Future project development and community content

Ready to Dive into Electronics?

Whether you’re a seasoned electronics pro or a curious beginner, the LED USA Flag Electronics Assembly & Learning Project will ignite your passion for building while offering a rewarding, hands-on experience. It’s the perfect project to enhance your skills, show your patriotism, and create something lasting and beautiful.

Grab your soldering iron, source your components, and let’s get started.

American Flag Builders Kit 5 Pack $129.50

Circuit Board with High Quality Colorful Silkscreen Image

(Unpopulated Circuit Board)

(Populated Circuit Board)

LED American Flag Soldering Kit - 5 PCB Pack
$129.50

The First American LED Flag Designed by a U.S. Engineer -

Assembled by an American—You.

What’s Included in the Kit:

5 Custom PCBs – Precision-fabricated LED American Flag circuit boards

Included: Online, Downloadable, Parts List, Assembly Instructions, Schematic, Operational Theory, Troubleshooting & Repair Guide

What's Not Included in the Kit

Not Included: Electronic components and hardware

Please Note: You will need to source your own electronic components - LEDs, Resistors, Shockley Diode, Wire, 24V Connector, 24V Power Supply

Enclosures Sold Separately

Pricing Basic Kit:

PCB 5-Pack: $129.50 (shipping included to U.S.)

Enclosure 5-Pack: $129.50 (shipping included to U.S.)

Note: U.S. import duties may apply and are collected by the carrier. Estimated tariff cost is typically under $10 per shipment, depending on current rates and carrier processing fees.

Coming Soon!

LED American Flag
Circuit Board Assembly Parts List

LED American Flag Circuit Board Parts List

LED American Flag
Circuit Board Assembly Guide

Bottom-side Circuit Board Assembly Instructions

Equipment Required
Safety Glasses
Soldering Iron / Soldering Iron Stand / Wet Sponge
Rosin or No-clean Flux Core Solder
Tweezers

Components Required
27 PCS, 510 Ohm, Surface Mount Resistors 1206 Package
1 PC, Shockley Diode - SS34 Surface Mount (D0-214) Package

Engineers Notes:

Safety Notes:

Age Recommendations:
The American Flag Soldering Kit is intended for ages 16+ with qualified adult supervision. Users 18 and older may operate it independently but use at your own risk—you are solely responsible for your safety.

Mandatory Safety Requirement
All users—regardless of age—must read this websites Home Soldering Safety Course before beginning assembly.

Recommended Soldering Equipment & Supplies

Soldering Iron Tip: Use a conical tip for best results.
Tip Maintenance: Clean and tin the tip with a wet sponge and wire solder (rosin or no-clean flux core). If the tip cannot be properly cleaned and tinned as described in the assembly instructions, replace it with a new tip.
Solder: Use wire solder with rosin or no-clean flux core. Choose the thinnest diameter available for precise control over solder application.

Soldering Iron Preparation Process

Step 2: Soldering Iron Preparation Process

Power On and Heat Up Turn on your soldering iron and allow it to fully heat up to the appropriate soldering temperature.
Test the Tip Apply a small amount of solder to the tip. It should melt almost instantly—this confirms the iron is hot enough for soldering.
Tin the Tip Coat the tip with solder until a noticeable layer forms. This process is called tinning and helps improve heat transfer.
Clean the Tip Wipe the tip across a damp sponge to remove excess solder. Drag the tip gently along the sponge surface until it appears clean and shiny.
Repeat as Needed Repeat the tinning and cleaning process as many times as necessary until the tip has a smooth, shiny finish—like it's been lightly painted with solder, but without any excess buildup.

PCB Bottom-Side Unpopulated Bare Circuit Board-
Showing Surface Mount Component Locations

The component locations for resistors R1–R37 and Shockley diode D1 are printed on the bottom side of the circuit board.

Step # 1
Locate Surface Mount Resistor Soldering Pads

Step 1: Locate the Surface-Mount Resistor Pads
Identify the soldering pads designated for surface-mount resistors on the bottom-side of the PCB. These pads are labeled R1 through R37 and are illustrated in the reference diagram above.

Step # 2
Prepping the Solder Pad

Prepping the Soldering Pad for Surface-Mount Resistor Installation

Tin the Soldering Iron Tip - Begin by applying a very small amount of solder to the clean, heated tip of your soldering iron. Do this by gently pressing the solder wire against the hot tip until it is lightly coated, just enough to appear slightly wet with solder.
Tin the Soldering Pad - Identify the narrower of the two soldering pads designated for the surface-mount resistor. Press the tip of your soldering iron gently onto this pad.
Apply Solder to the Pad - While maintaining gentle pressure with the iron on the pad, press the solder wire at the point where the iron tip meets the pad. After a second or two, the solder should melt and begin to coat the pad.
Form a Proper Solder Bump - Your goal is to create a smooth solder bump that fully covers the pad. It should not form a round ball, as this indicates improper bonding. The soldering iron must remain in contact long enough for the flux within the solder to clean the pad’s surface. Once the pad reaches soldering temperature, the solder will bond mechanically to the pad.
Troubleshooting If the solder does not melt and bond within 5 seconds, stop. Clean the tip of your soldering iron using a damp sponge, reapply a small amount of solder to the tip, and repeat the process. Continue until the pad is properly tinned with a smooth, shiny bump of solder.

Step # 3
Initial Placement - Tack Soldering the Resistor to the Pad

Step 2: Tack Soldering the Resistor to Its Pad

Follow the same procedure outlined in Step-2 to prepare your soldering iron tip.

Using a pair of tweezers, grasp the surface-mount resistor by the sides of its body.
Align the resistor so it is centered between the two soldering pads and lies flat against the circuit board.
While holding the resistor in place, heat the soldering pad that was previously tinned.
As the solder melts (reflows), it will bond to the metal contact on the end of the resistor.
Once the solder becomes molten and attaches to the resistor’s contact, remove the soldering iron.
Continue holding the resistor in place with the tweezers until the solder cools and solidifies — about two seconds.
After cooling, release the resistor. One end should now be tack-soldered to the pad.

This entire process should take only a few seconds: approximately two seconds to reflow the solder and two more seconds for it to cool and set.

Step # 4
Soldering the Opposite Side of the Tack Soldered Resistor

Step 4: Soldering the Opposite Side of the Resistor

Using a clean, tinned soldering iron with a slightly wet tip, heat both the unsoldered side of the resistor contact and its pad simultaneously. Feed solder directly into the point where the soldering iron tip, pad, and resistor contact meet.

The solder should flow smoothly, covering the entire pad and bonding the resistor contact to the pad. Once the solder has flowed evenly, remove the soldering iron and allow the joint to cool for at least 3 seconds so the solder can solidify.

If rework is needed, clean the soldering iron tip before trying again. Any excess or burned solder residue on the tip can prevent proper heat transfer and result in a poor-quality solder joint.

Step # 5
Reflowing the Solder Joint of the Tacked-Side of the Resistor - Completing the Resistor Soldering Process

Step 5: Reflowing and Final Inspection

Using a clean, slightly wet soldering iron tip, reflow the resistor’s solder joint by positioning the iron so that it makes contact with both the resistor’s metal terminal and its solder pad. Apply a small additional amount of solder to the joint as needed. Once the solder flows and covers the pad evenly, remove the soldering iron tip and allow the joint to cool.

Visually inspect both solder joints and rework if necessary, always starting with a clean soldering iron tip.
Important: If you rework one side of the resistor’s solder connection, allow at least 4–5 seconds before reworking the opposite side. Attempting to reflow both sides before the first joint has cooled and solidified may cause the resistor to shift out of alignment or become dislodged from the pads.

Shockley Diode D1 Installation Procedure

Step 3: Tack Soldering the Diode into Place

While continuing to hold Diode D1 in position—aligned between its two solder pads and flat against the circuit board—with one hand, use your other hand to hold the soldering iron.

Heat one side of the diode’s metal termination until the solder beneath it melts. Then, carefully remove the soldering iron while maintaining the diode’s position until the solder cools and solidifies, securing that side of the diode in place.

Step 4: Soldering the Opposite Side of the Tacked Diode

Allow enough time for the tacked side of the diode, solder enough time to fully cool and solifiy prior to releasing the body of the diode, with your tweezers. About 5-7 seconds, at which time you can release the body with your tweezers.

Then heat the contact opposite of the tack soldered side with your soldering iron while feeding a small amount of wire solder into where the contact and soldering pad meets.

PCB Bottom-Side Fully Assembled

Topside Circuit Board Assembly Procedure

PCB Topside Bare Board

Important Please Note:

Red, white, and blue LEDs are polarized components, meaning they must be installed in the correct orientation within a circuit to function properly.

Refer to the circuit board assembly illustration above for the correct LED orientation.
Insert the shorter LED lead, the negative terminal, into the hole marked with a negative (–) symbol.

PCB Topside LED Component Location Guide

Procedure: Installing, Crimping, Trimming, and Soldering

Through-Hole LEDs

Materials Needed

Through-hole LEDs (Red, White, Blue)
Circuit board (PCB)
Soldering iron and solder
Wire cutters
Safety glasses

1. Identify LED Polarity

Anode (+): Longer lead
Cathode (–): Shorter lead, often marked with a flat edge on the LED casing
Check the PCB for polarity markings "-" near the holes.

2. Orient the LED Correctly

Insert the anode the long lead into the hole without a marking.
Insert the cathode into the hole marked with a "–" sign.

3. Seat the LED

Insert the LED into the designated holes on the PCB until the bottom edge of the lens sits flush with the top surface of the board.
While holding the LED firmly in place from the top side, use your fingers to bend each lead outward at a 90-degree angle on the underside of the PCB. Bend the leads in the direction of the rectangular soldering pads, ensuring each lead overlays the pad as close to the center of the pad, and as close to the board surface as possible.
This manual bend secures the LED in place, keeping it tightly flush against the circuit board and preventing any movement during soldering.
Trim the excess length of each lead so it does not extend beyond the soldering pad, allowing for a clean and reliable solder joint.

5. Solder the Leads

Heat the pad and lead simultaneously with the soldering iron
Apply solder until it flows and covers the pad and lead
Remove the iron and let the joint cool.
Avoid cold solder joints (dull or cracked appearance)

7. Final Inspection

Visually inspect you solder joint for defects, rework as needed.
Test the circuit to confirm LED functionality.

PCB Topside Fully Assembled

INTRODUCING THE AMERICAN FLAG LED SOLDERING KIT / LEARNING PROJECT