abse/museair-usb

docs/research/led-light-pipe/SELECTION.md

# Purchased status LED light pipe — 10 October 2026

Candidate: **Bivar PLP1-200**, clear, rigid, rear-insert panel press-fit light pipe. The printed custom light pipe has been removed from the lid and from assembly model generation. No homemade substitute is shown as a purchased part.

- Manufacturer product: https://catalog.bivar.com/item/rigid-panel-press-fit/plp-series/plp1-200
- Manufacturer drawing: https://www.bivar.com/parts_content/Datasheets/PLP1-XXX.pdf (rev U; local copy Bivar-PLP1-XXX.pdf).
- DigiKey search: https://www.digikey.com/en/products?keywords=PLP1-200
- Mouser search: https://www.mouser.com/c/?q=PLP1-200
- Mouser product locator: https://www.mouser.com/ProductDetail/BIVAR/PLP1-200

Manufacturer dimensions verified: 3 mm round lens, nominal 0.200 in / 5.08 mm body, 3.81 mm flange diameter, 1.27 mm flange thickness, 4.064 mm head length measured from flange seating plane, 2.845 mm input stem diameter. Panel thickness range 0.047–0.093 in (1.194–2.362 mm), so the 2 mm lid qualifies. Recommended hole is 0.121 +0.003/-0.002 in (nominal 3.0734 mm; permitted 3.0226–3.1496 mm). Printed holes require measurement/reaming to achieve the interference fit.

At the unchanged LED center X=-11.5, Y=18.5 mm, lid inner face Z=45 mm puts the input at Z=39.92 mm. The actual imported KT-0805G model's top is Z=39.4100 mm: nominal optical gap 0.5100 mm. Flange is behind the lid, Z=43.73–45 mm; purchased lens extends to Z=49.064 mm, 2.064 mm above the lid. Keep it as a separate purchased assembly part when its real CAD is obtained. The current assembly leaves this hole empty; no supplier geometry has been fabricated or mislabeled as OEM CAD.

D1 is **green** (KT-0805G / JLC C2297); a clear pipe carries that green light outside. A red-tinted cap cannot turn a green LED red and may significantly attenuate it. A genuinely red indicator requires selecting a red LED and a separate electrical/BOM change.

Access limitations: DigiKey and Mouser returned HTTP 403; Amazon returned HTTP 503. Manufacturer catalog and drawing were readable. Distributor availability and current price were **not verified**. This is a dimension-checked sourcing candidate, not a stock/price quotation or a purchase. Physical optical coupling, printed-hole fit and tolerances require the actual part.