6th Annual Scratch Made Light Contest - Flashy Mike's machined project

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MRsDNF
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I know it is a failure but the detail you put into the piece looks impressive. Beer

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

thijsco19
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Flashy Mike wrote:
So do I. Got it this afternoon, made some test prints, and printing of the lower housing with this new PETG is currently in progress. Looks good so far but at that stage the ABS print did also look good. Anyway, I redesigned the housing to print it faster (e. g. got rid of the knurling and made thinner walls) so it should be done after 5 hours at max.

Whatever you do, 3d printing is some weird black magic stuff.

How do you like petg? (Compared to pla?)

Flashy Mike
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Success LOL
I know its not too beautiful but it works. Haven’t printed PETG before and I’m pretty impressed. Of course there was a lot of stringing but layer bonding is pretty tough. This component is only about 37 grams, flexible but strong. As you can see, I did a redesign of the housing. The lower housing is printed in 2 parts now. The outer one has been stripped down to achieve shorter printing times. I omitted the knurling – it did look pretty well but it increased printing time a lot and needs thicker walls, and my spare time is limited currently. I still have to finish the design of the inner part, printing this part will be less demanding since its usually hidden.

@thijsco19: The reason why I’ve chosen PETG over PLA is the higher heat tolerance and the stronger layer bonding.


MtnDon
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Hooray!!! Thumbs Up

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pinkpanda3310
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Good to see you work around the problems you faced. Grad Well done

lostheplot
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interesting build

sorry all images down
thanks photobucket

Flashy Mike
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Fails and wins printed so far. I’m not sure if I’ll finish this project in time since now I’m too busy with family activities until Monday.

MtnDon
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An impressive number of pieces.

Can you share what software you use and how difficult was it to learn? And if you don’t mind me asking, is the use of 3D printing something you do at work or simply something you learned because you are interested? Thanks, I have been curious about 3D for some time, but learn better by doing than by reading.

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Flashy Mike
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I’m interested in 3d printing for years now and since it gets more and more affordable I bought my first cheap printer this summer. I tinkered with electronics and software all my life (privately and commercially) and this 3d printing actually offers many oportunities I was missing the past years – particularly since my hand crafting skills and my patience are somewhat underdeveloped. And I have 2 kids who are also interested in this and other technologies.

My first 3d designs I created with Tinkercad which is great for beginners. But soon I was missing advanced options which I found in Fusion360 (free for private use). Tinkercad is easy to learn, Fusion360 is not due to its unique user interface. I had a hard weekend with much cursing and swearing when starting with this software, although I’m a software engineer by myself.

Its pretty easy and encouraging to create and print the first simple designs, and if you learn rather by doing than by reading you should try it. For advanced designs and more beautiful prints you have to do lots of reseach though – but there are many sources of knowledge and many people eager to help, just as in BLF.

In addition to a design software you need a slicing software which prepares the designed object files for printing. It “simply” calculates the path the print head has to go. Currently I use Cura and Slic3er (no typo), they are good but not perfect, and for better results there are many tuning options. Both are free.

MRsDNF
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You have the makings of a work of art there FM.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

FmC
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Man, after all this I hope you are able to get it together.

Maybe we could all vote for a weeks extension to the comp…. Innocent

Flashy Mike
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I’ve finally sucessfully printed all large and most of the smaller parts. Since I modified the design and made upper and the lower casing two parts each I was able to use the green ABS for the shells as primary intended. The blue components are made of PETG which is also more heat resistant than PLA.
And I assembled the light the first time right now. Electronics not yet inside. Don’t mind the orange thing in the middle, its just a printed placeholder for the final copper disk which I still have to drill and file. Did I mention my missing handcrafting skills and patience? Fortunately only a small ring of the copper can be seen in the final build so hopefully people don’t notice my handcrafting disability …

Closed lantern:

Opened:

Bottom view (the orange triangle is a printed tool for dis/-assembling):

The electronics compartment. You might notice that the bottom plate has threads at the outside and in the center. This should ensure the o-rings pressed tightly for proper water protection. Magnets still missing, haven’t arrived yet.

pinkpanda3310
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Very nice Thumbs Up looks like you’re on the home stretch. I wouldn’t worry too much about your hand skills. End product will be awesome Wink

MtnDon
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Looks good, Mike

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CRX
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Cool Thumbs Up

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Nice Shocked Good looking Wink

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MRsDNF
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That looks super impressive FM. Its coming along nicely now. I’m guessing its about 3.5’‘ in diameter?

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Flashy Mike
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MRsDNF wrote:
That looks super impressive FM. Its coming along nicely now. I’m guessing its about 3.5’‘ in diameter?

Thanks! Its 102 mm in diameter with a height of 56 mm closed and 130 mm fully extended (excluding the lanyard mount on top).
And it already feels more heavy than expected. I guess it will be about 400 grams finally with copperplate and cells.
FmC
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Hope the magnets turn up soon.

Very creative build, & good to see some new tech entering the Comp. Thumbs Up

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Looks good. I hope all your parts arrive soon!

The Cycle of Goodness: “No one prospers without rendering benefit to others”
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Flashy Mike
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Well, the circular 20×2 mm magnets are still missing. Yesterday I ordered other ones locally from Amazon, they should arrive tomorrow. These are smaller though, only 15×2 mm. Dependent on which batch arrives first (if any), I have to reprint the bottom plate.

Managed to finish the copper disc. Not too beautiful but functional. Was a pain, hands and arms do still hurt. Only minor injuries though … Facepalm

I borrowed a step drill from a friend for the 28 mm center hole. For the small holes and the first steps of the center hole I used a small hand drill until it’s cells were empty. Didn’t want to wait for charging, so I took my fat and heavy hammer drill for the last steps. Both without drill mount and bench vise (which I don’t own). I screwed the copper disc on top of a wooden block before in order to be able to keep it in place with one hand.

There are still some smaller parts to print, I hope I’ll finish printing today.

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Flashy Mike wrote:
Managed to finished the copper disc. Not too beautiful but functional.

Must look worse in person. It looks fine to me, in the pic. In fact, I can’t find anything wrong with it. It looks like a manufactured part.

How much filament does it take for the bottom plate? If it isn’t too costly, you could go ahead and print the other plate, so that when your magnets arrive, you will be all ready to use whichever size you get in hand first.

The Cycle of Goodness: “No one prospers without rendering benefit to others”
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Flashy Mike
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DavidEF wrote:
Must look worse in person. It looks fine to me, in the pic. In fact, I can’t find anything wrong with it. It looks like a manufactured part.
Well, my sense of self is somewhat damaged after watching too many of CRX’s builds (which are pure perfection). Big Smile

DavidEF wrote:
How much filament does it take for the bottom plate? If it isn’t too costly, you could go ahead and print the other plate, so that when your magnets arrive, you will be all ready to use whichever size you get in hand first.
Its not a question of costs, less than 50 ct for the plate. But I don’t know how strong the magnets are. I would rather like to check first how many of them I need for the lantern before I do the redesign and printing.
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Well, not quite but I am getting better Big Smile
Copper plate looks good, hope them Neo’s arrive soon Smile Thumbs Up
N35’s? 15mm x 2mm should be fairly strong.

Flashy Mike
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Not much time left, getting somewhat nervous …

Finally got the locally ordered magnets. Designed and printed a new bottom plate and the disks which cover the magnets. Glued magnets and disks in.

And I assembled the upper part of the housing.

I married upper and lower part. The clear battery holder is – like the green components – made of ABS. All parts touching the hot copper disk are printed with ABS filament now which should withstand temperatures up to 100 °C. All other parts are PETG with a heat tolerance of up to 70 °C. The RGB status LED and the USB-Connector are glued in and sealed and should provide water protection.

I checked driver, bluetooth transmitter and charging board, everythings works well of so far. Tomorrow I will put the electronics in the housing, too tired now, its after midnight here. Hopefully the lantern will be completed tomorrow, I need the last day of the contest to make a video showing the remote function.

MtnDon
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Way cool!!! Looking forward to seeing the finished product video

Makes me want to get a 3D printer.

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MRsDNF
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MtnDon wrote:
Makes me want to get a 3D printer.

You dont need a printer Don.

Its amazing the parts that marry together to make your lantern FM. Looking good. Beer

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

FmC
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Keep going, almost there!! Thumbs Up

pinkpanda3310
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Looking good seeing some parts fitted together Thumbs Up

Flashy Mike
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I’m using a 5mm RGB LED (common anode) to display charging status (red and green) and bluetooth activation (blue). This is ok with the charging module since it pulls down the LED’s cathodes with open collector circuits. Unfortunately my bluetooth module is powered directly by an output port of the Attiny85, and I have to use this pin also to drive the blue LED since all other ports are in use. So I quickly soldered this open collector circuit with a NPN transistor I had lying around. Do you notice the little 603 resistor between base and emitter?

… and wrapped:

The driver PCB in place with a printed spacer. The space under the PCB is filled with heat conducting cubes to ensure a good thermal connection between driver and copper disk, both for cooling the 7135 and thermal regulation.

The bluetooth board sandwiched on top of the driver with another spacer on top.

Inserted cells and the charging PCB which sits firmly in grooves. Soldered a lot of wires …

Before screwing in the botton plate this blue printed part is plugged in, it fixes the cells in axial direction and presses the boards sandwich firmly to the copper plate.

And – finally – my camping lantern is finished!

More pictures and a video to follow …

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