How hard would this be to draw in CAD and get built?

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fortyfiveautomatic
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How hard would this be to draw in CAD and get built?

I know many of you flashaholics are engineer/machinist types, so I thought I'd ask for some advice about building a heatsink for my busted Dorcy light.

With my noggin and some crappy drawings, I have designed a basic prototype and what it should look like:



It's designed to fit in the flashlight tube with a certain internal diameter (referred to in the diagrams as diameter "b"), and fits flush with the head of the heatsink press fit against the thin diameter metal at the end of the flashlight tube (diameter "a").

Flashlight tube:





In the colored paint diagram, diameter "c" is going to be the same diameter of a circular pcb containing the led.  Diameter "d" is for the circular current driver circuit board.  Missing from the diagrams are the dimensions for the thicknesses of the LED pcb and the driver board.

The dotted lines in the cross-section diagram represent holes drilled to connect wires from the current driver to the LED.

My questions:

1. How difficult will it be for someone like me, a non-engineer with no CAD experience, to draw this up in such a program?

2. How hard would this be to machine this out of, say, aluminum or brass?  Could it be done on a lathe or will the latest multi-axis CNC tech be required?

3. Provided I can draw it up and provide the metal stock, how much would it cost to cut it to this spec?


Thank you for any insight you can provide.

SecaRob
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fortyfive,  if you could give me the dimensions I could draw it up in autocad in just a matter of minutes.  Cant help you with the other items.

fortyfiveautomatic
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Really?  Wow thanks, SecaRob!

Unfortunately I don't have the driver board but I am using a 1050mA AMC-7135 board.  Mostly I just wanted to get an idea of the difficulty of such an undertaking.


I will dig up the calipers and get you some dimensions tomorrow.

okwchin
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Totally doable on a standard lathe, and a press drill. The only critical dimensions are the inside diameters of the torches, and the driver diameter.

"like everyone else - I’m looking for my next “last” flashlight" -  ohnonothimagain

fortyfiveautomatic
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Here are the dimensions.  I had to make a slight modification to the original drawing:

PilotPTK
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Any competent machine shop can make this for you in no time.

https://docs.google.com/leaf?id=0BxO1D0PgqwgpZWRjODY4MWEtZTQ4NS00ODkxLTg...

https://docs.google.com/viewer?a=v&pid=explorer&chrome=true&srcid=0BxO1D...

 

The first link is to an IGES Model, the second is to a 3D PDF File.  Once you open the link, Download the files.  In the 3D PDF, You can drag the model around using your mouse to see it in any 3d view.

 

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

fortyfiveautomatic
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I very much appreciate your efforts!

You were right -- it didn't take long at all, and it is already on its way.  I will post a complete report of the finished project.

 

Again, thank you for the time and effort you put into this Smile

PilotPTK
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It was my pleasure.  You drew it up quite well, really.  It literally took me about 90 seconds to create it in 3D.

I'll look forward to hearing about the finished part!

Good luck with it,
PPtk 

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.

sontakke
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Wow, that 3D model in PDF looks great.