A Custom Milled Jig for Smart Bulb Programming


Who would have thought that some day we’d need programming jigs for our light bulbs? But progress marches on, and as there’s currently a number of affordable Internet-controlled bulbs powered by the ESP8266 on the market, we’re at the point where a tool to help update the firmware on the light over your kitchen sink might be something nice to have. Which is why [cperiod] created this programming jig for AiLight smart bulbs.

Flashing the AiLight bulbs is easy enough, there’s a series of test points right on the face of the PCB that you can hook up to. But if you’re updating more than one of them, you don’t want to have to solder your programmer up to each bulb individually. That’s where the jig comes in. [cperiod] says there are already some 3D printed designs out there, but they proved to be a bit finicky.

The design that [cperiod] came up with and eventually milled out on a 1610 CNC router is quite simple. It’s effectively just a holder to keep the five pogo pins where they need to be, and a jumper that lets you toggle the chip’s programming mode (useful for debugging).

The neat trick here are the “alignment pins”, which are actually two pieces of 14 gauge copper wire that have had their ends rounded off. It turns out these will slip perfectly into holes on the AliLight PCB, ensuring that the pogo pins end up on target. It works well enough that you can hold the bulb and jig in one hand while programming, it just needs a little downwards pressure to make good contact.

We’ve previously seen how easily you can replace the firmware on some of these ESP8266 bulbs. While there’s certainly a downside to these bulbs being so simple to modify, it’s hard to deny their hackability makes them very appealing for anyone looking to roll their own network-controlled lighting system.