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@Robert
Hi Gordon,
Thank you again for your answers!
Charlieplexing would have been a solution, however that would mean tearing up the currently glued in LEDs and wires. Also I am not sure, if I want that extra complexity in the code. Adding the display flip already slows down LED walk and buzzer sound intervall noticeably.
Unfortunately 5mm LEDs do not fit into the 3D printed wings and I do not have the skills to change the CAD data. Looking at the WS2811 there probably also would not be enough space in the wings to fit those. Even the 3m LEDs + wires were tight.
So I am probably going to try your third proposal: Thinner wire. Currently I use 0.14mm2 stranded wire with PVC isolation. Likely 0.08mm2 stranded wire with silicon isolation would perform much better. Hopefully I can poke it into the board when I double-fold and solder it.
But as I have now gifted the device to my brothers son, I am not sure when I will have the opportunity to test that. :-)
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