Alpg88 2019 Old-Lumens Challenge Entry, machine category

I will enter this years Old-Lumens Challenge in machine category, i will be building a light using 3D printer. i only learned a small part of a simple 3d design software, but i feel this should be enough to make a relatively simple light.
so far i have no solid plan, only some details to build a light around. it will be 4 triples, 2 will be warm white xpg3, 2 others will be color, uv, red amber, and white. i will use rgb driver, the light will have white\amber strobe, as well as red, and uv leds, it will be powered by several 18650 in parallel, with usb charging. warm white leds will be running of linear drivers, there will be 2 modes for warm whites. i will be using ledil triple optics, with narrow angle. i will be using abs filament. i will use aluminum angle for a heatsink. the shape and possible other functions will come “as i go”
unfortunately this year i can not use my favorite material, plywood, due to newborn in the house, i can not set up a “wood shop”, but fortunately, i acquired an interest in 3d design. thanks to a member of this forum. and will use my newly acquired knowledge to participate in the contest.

:+1: :slight_smile:

Nice to see you enter :+1:

thanks guys.

here are some parts that i’ll be using, and first sketch of the light.

i will need to buy a roll of filament, i’m thinking orange color,

When I grow up I’m going to be able to draw like that. :beer:

Thanks, believe it or not, a month ago i had no clue how to draw a line on computer. this program is very simple, all i know how to do is to take primitive shapes, alter them, cut and combine. there is so much more to that software that i do not know, maybe next year i’ll learn how to do more complex shapes.

Welcome to the comp alpg88. Looking forward to what you build :slight_smile:

In my very limited experience with drawing I’ve found that slicer softwares (for 3d printers) are more user friendly than cad/cam (for cnc mills etc…).

Glad to see you’re joining! Looking forward to seeing the process and result.

Welcome aboard :slight_smile:
It looks like you are tackling that learning curve great! The best part of 3D design is the relaxation that comes with being able to undo anything. It’s freedom :smiley:

printed a test part, to see how patterns show up, and how it shrinks, overall pleased with result, patterns do show up, hopefully acetone fume smoothing will leave some of it, and it did shrink, 160mm side became 158.5mm, 12.1 became 11.9, and 37, became 36.7mm. will adjust the part’s dimensions accordingly.

i also realized, if i perint 2 parts that supposed to fit together in different positions, then Y becomes Z and x becomes Y, so shrinkage will not be the same, and parts will most likely not fit. so i have to print them in same positions, but then i got another dilemma, if i print sides standing up, thin parts may not print right, i had that happen with long thin parts, i will also have bad finish on the bottom. so i may have to split the core in half, print 2 halves separately, and then join with acetone. or i can join 2 sides with small pegs and print both as one part, i will print 30% size test print to see how it comes out.

Looking good :slight_smile: . I too used to print ABS and shrinkage was always frustrating.
On another note, the magic number for clearance is about 0.25mm. So if you want to put a cover down in a recessed area, subtract 0.5mm off the height and the same off the width of the inner piece. That should make them go together and come apart as expected.

Nice project, alpg88. The light has an interesting form. :sunglasses:

You will use enough aluminium, right? If you drive those triples with some current there will be plenty of heat.

yes it will make heat, should be enough aluminum to dissipate low-mid current, but high, only for short time, i will have to install a thermal sensor to drop down current.

also i found out small raised letter are not showing up, slicer does not even process them, but with letters that are sunk, it works just fine, i had to lower each letter so they show up on a slicer.

Welcome to the party :smiley:

Good idea, yes. Good luck with your build! :crown:

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May I ask if you have tried AutoDesk Fusion 360 cadcam software ? It is FREE for Hobbyist to use. :smiley:
I’m just drawing with it now and its easy to learn.
Nice project. :+1:

finished designing parts, so far printed 3 parts, in black abs, side covers, and the head spacer,

the head spacer will be pressing on the tir, thus pressing on the mcpcb, i wont need to use any screws or glue, just thermal paste. there will be an o ring around each led, so glass will press against it, and create a seal between outer window and the spacer.\

the core will be printed in 2 parts, i wanted to use orange abs, got a roll of ic3d stuff, but it does not want to stick to the bed, so far, will try some other stuff, if not will have to replace the abs, black hatchbox printer beautifully, stock to the bed with glue stick every single time,. i want to do 2 tones, black side covers and head, orange core and switch cover.
charging will be done usb port, one side cover will have a sliding door, that will open up a port.

Great progress alpg88 :+1: I hope that aluminium angle will be enough heatsinking