While these aren't RGB pixels, the process is the same for any panelized design I create, including the layout for the WS2801 + SMD RGB pixel in this thread. I needed to make 630 bright green LED pixels and rather than buying the LilyPad pieces (https://www.sparkfun.com/products/10046
) which would've cost me upwards of $500, I decided to make my own. On a 50mmx50mm piece I can cram 23 of them: a grid of 7x3 plus two extra to fill the rest of the board.
Production of boards was $30 + $5 shipping. LEDs and resistors just over $200. My time: priceless.
Here's me cutting a single board into pieces, takes me a little over 2 minutes each (I already trimmed off the extra two that are along the top edge of each board). I should point out that these are 0.8mm FR4 boards, however the WS2801 pixels I created above were done on 2mm FR4 boards. Cutting is just a bit slower for those.
Sorry for the delayed reply, I just moved to my first (owned) home so I've been slammed the past few weeks. That's an awesome video! I have a dremmel on my wish list, but I think that sort of cutting may be out of my level until I get some better gear (and experience). I could probably order a board pre cut tho.
You had mentioned bending the LED's using the module you have.
Like I said, you could just take a regular 3mm through hole LED, bend the bottom 3-5mm of the legs at a 90 degree angle and solder that to the boards I created.
Do you still have a few spare of these available? If I could use this technique to piece together a small 4 or 5 string light, I'd have the confidence to order all the rest of the parts I'll need. (part of my problem is I want my boss to pay for the bulk order once I know for sure what I'm doing, this is a team morale project:p) I would certainly be willing to pay for the parts, I just don't need the whole gambit.