Displays are crucial to modern life; they are literally everywhere. But modern flat-panel LCDs and cheap 7-segment LED displays are, well, a bit boring. When we hackers want to display the progress of time, we want something more interesting, hence the plethora of projects using Nixie tubes and various incantations of edge-lit segmented units. Here is [upir] with their take on the simple edge-lit acrylic 7-segment design, with a great video explanation of all the steps involved.
Engraving the acrylic sheets by hand using 3D printed stencils
The idea behind this concept is not new. Older displays of this type used tiny tungsten filament bulbs and complex light paths to direct light to the front of the display. The modern version, however, uses edge-lit panels with a grid of small LEDs beneath each segment, which are concealed within a casing. This design relies on the principle of total internal reflection, created by the contrast in refractive indices of acrylic and air. Light entering the panel from below at an angle greater than 42 degrees from normal is entirely reflected inside the panel. Fortunately, tiny LEDs have a wide dispersion angle, so if they are positioned close enough to the edge, they can guide sufficient light into the panel. Once this setup is in place, the surface can be etched or engraved using a CNC machine or a laser cutter. A rough surface texture is vital for this process, as it disrupts some of the light paths, scattering and directing some of it sideways to the viewer. Finally, to create your display, design enough parallel-stacked sheets for each segment ..
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