SECTION 3: 3D PRINTING
I've been interested in 3D printing ever since i first heard about it many years ago, but it's only recently that i've been able to make use of it thanks to sites like Shapeways; where 3D models can be uploaded and then printed in any one of a number of material options.
My first plan for a 3D printed torch was to be a AAA, based around the same architecture as the brass AAA torches seen in Section 1. At the time the only metal Shapeways provided which was suitable for making torches from was sterling silver. However, to test the design before i went for the expense of silver, i redesigned the model slightly so it could be printed in plastic. This required a copper contact to be installed into the plastic torch body to complete the electrical circuit that, in my previous AAA torches, was being made by it's brass body.
Although these prototypes proved that a 3D printed torch host was perfectly doable, i realised that i didn't really like the design; it looked just like my other machined lights, rather than taking advantage of 3D printing's ability to make shapes that couldn't be achieved any other way.
I therefore set about redesigning the AAA light into something a little more elaborate. Meanwhile i considered that the high cost of the silver parts would be rather let down by the low performance of the internals it was designed for, so i also set about designing a high performance light that could make the most of silver's excellent thermal properties.
This light turned into my 'Ag Torch'.
Specs:
Full sterling silver body construction with 5mm of silver behind the LED,
Gold plated brass bezel and tail rings,
XM-L U2 on copper MCPCB from LED-Tech.de,
Carclo 10003 20mm optic,
3 Amp 8xAMC7135 driver from Illumination Supply, set to l/m/h,
AW IMR16340,
McClicky tail switch with extra spring for switch cover,
Six 6x2mm tritium vials in the switch cover.
The torch manages to get almost too hot to hold within a minute, which i suppose just shows how much heat isn't being moved away from the LED by other torches with the same components.
The next version of my 3D printed torch turned out yo be a little more interesting.
Having decided that i was happy with this new design i pressed ahead with a silver version.
It could do with a better polish (which Shapeways now offer as a premium option) but overall i really like it.
I decided that it needed a proper LED drop-in so i built a direct drive copper pill with an XP-G R5 on a ceramic MCPCB and an aspheric lens.
I liked the silver one so much so that i also ordered a gold plated one.
This is about where i've got to with 3D printing torches so far.
Tofty's 3D Printed Torches on Multitool.org,
Tofty's 3D Printed Torches on Cautious Pig Farmers
I've also experimented with printing some torch related accessories, such as tail shrouds and diffusers, for both my own torch designs and for some production models.
Although only barely light related, i've also come up with some nice little 3D printed tritium lanterns.
Come on down to Tritium Town!
That's not quite it for 3D printed items as the next section will testify.
In case your not too familiar with 3D printing.....
Shapeways is a company which manufactures objects, from a customer's upload 3D model, using 3D printing.
I think it's great, all i have to do is create a 3D model that conforms to the desired materials physical limitations, upload it, pay for one to be made then sit back and wait for it to be delivered. It's the future and i'm all for it being that simple.
The plastic torches are either glued or laser sintered together from layered powder, then polished in a ceramic tumbler which also helps remove excess powder from voids and cavities.
The silver and brass torches are not technically printed, they're cast using the lost wax method. It's the wax models that are printed. They are then finished by removing the sprues, polishing and/or plating.
Shapeways also offer a stainless steel material which i've been using to make various one-piece multitools and such. It's production starts out very similar to the plastic material with a stainless steel powder being glued together to form an overall shape. The object is then heated in a kiln to burn away the glue and fuse the stainless particles together. At the same time the object is infused with bronze to fill any voids. It's not a suitable material for torches, as it's resolution isn't quite good enough, but it's a lot of fun for other things.
Updates will continue until morale improves.