DIY Halloween RGB LED Kitty Ears


Posted By Solarbotics

Oct 10th 2016

ears-banner2Simple cosplay cat ears made out of Fosshape, decorated with rhinestones and complete with RGB LEDs for color changing effect.

Materials:

  • Fosshape 300
  • 2 x slow scroll RGB LEDs
  • 2 x CR2032 coin cell batteries
  • 2 x coin cell battery holders
  • 100 flatback rhinestones
  • 2 x hairclips
  • fake fur
  • steel ball chain

Tools:

  • scissors
  • heat gun/steamer
  • glue gun
  • needle and thread
Step 1: Cut out the paper template

Define the height you want the ear to be - by holding a ruler up to you head (highly scientific approach) - and build a triangle similar to shown. You can use these shown measurements as a guidelines - but your proportions might be a little different.

Adjust the shape to have the curves following a more natural outline of the ear. Cut out the paper triangles..

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Step 2: Cut out Fosshape

Trace the template onto the Fosshape. Cut out 2 large shapes and 4 smaller shapes for the base of the ear (two bases per ear).

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Step 3: Sew the ear parts together

Sew each ear shape to one base:

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Step 4: Harden the Fosshape

Now shape and harden the ears using a steamer or heat gun. They will shrink about 1.5 times (left ear treated with heat and right one not yet shown for comparison), so take that into consideration when choosing the final product size.
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Step 5: Attach the hair clip

Sew the second bottom to the ear and insert the hair clip. Heat shrink the bottom layer.

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Step 6: LED

Insert the LED into the inside of the ear with legs poking out from the other side.

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Step 7: LED Batteryimg_20161111_151534
Insert the legs into the battery holder so that the longer (positive) leg is closer to the outside.
 
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Insert the battery (positive side facing out) - it should be very snug. If everything is done correctly, your LED should light up right away. If not, then readjust the LED legs until the light is on.
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Bend the LED legs as shown above, kind of in a Z shape: 1st bend near the top of LED, towards the top of the ear, and second the opposite direction so that the whole contraption sits flat against the surface.
 
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Stitch the holder down using the holes provided. Use some hot glue to secure the holder to the fabric if needed.

Step 8: Rhinestones

Now the fun part - use hot glue to attach the flatback rhinestones to the inside of the ear.

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Step 9: Fur

Use small tufts of fake fur to disguise the bottom of the ear. Sew them in place.

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Step 10: Finishing
Optional - use some cord/ribbon (in this case a ball chain) to finish the ear edges!

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