Should I consider transistor saturation voltage when calculating LED's resistor

The ULN2003A spec sheet should have a curve of saturation voltage VS current so you can get an accurate idea of the voltage drop.

Yes you should use 5.0 - Chip voltage drop if you want an accurate current to flow.

You also need to know the forward voltage VS current for the LED: that is also a curve not a fixed value.

THEN it's just simple subtraction and Ohm's Law :slight_smile: