xqwerty151x's Machine Made Class, 9th Annual BLF/OL contest

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xqwerty151x
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xqwerty151x's Machine Made Class, 9th Annual BLF/OL contest

Howdy guys,
I’m relatively new here and thought I would give the contest a shot. I am an engineering student and am working on designing a flashlight for class. I thought I would just post my progress here as well, any ideas and help would be appreciated.

My flashlight uses MTN Electronics 20mm quad MCPCB with SST-20 4000k emitters. I also am using a MTN 17DDm driver for the high output and moonlight mode. I am also planning for a side-mounted E-switch.

YuvalS
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Welcome xqwerty,
It is nice to see new members ion the machine made category.
Good luck, I am curious  to see you progress.

My FW repository

My BLF/OL contest entries: 7th 8th 9th 

xqwerty151x
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I primarily use Fusion 360 since that is my department's primary CAD software and have already drawn up some models.

These are some of the overall photos so far. I am currently working on getting the internal dimensions correct before working on the CAM and fabricating the parts. Once I can be sure the technical aspect of the light is solid I want to go back and refine it further.

raccoon city
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It's good to have you here, xqwerty151x!

There's a link in my signature on how to post pics on BLF.

EDIT:

Nevermind, you figured it out.

209_milla

xqwerty151x
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Yeah, this is my first time posting images here, but I figured it out, just an older system than I’m use to!

MtnDon
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Thumbs Up Welcome aboard! Entrant listed in the main 9th thread
CNCman
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Welcome to BLF xqwerty151x. Big Smile
That is a big project you have on the table. I this your first run thru Fusion 360 ?
Good to see you in the competition. Wink

xqwerty151x
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No, this is not my first time around the block. I have been using Fusion for a few years now, but also have some experience with Creo, Solidworks, and Inventor. I am a student tech at my University’s Engineering Design Center and work mainly with manual machines but also do some work with the CNC we have. I have some basic practice with MasterCAM but for the bulk of the CAM I will be working with one of the other student techs since I don’t have enough experience to post code to the machines.
I am in a computer-aided manufacturing class now so I hope to become more familiar with CAM software, but as of now only a few people can do CAM for the machines on campus, they cost too much for us to break every week.

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Good to see one more participant for the machine made category! Thumbs Up

Welcome to BLF, xqwerty151x, and good luck with your build.

I don’t know if it is too complicated but you may want to add a few cooling fins to your flashlight design.

xqwerty151x
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Howdy, Sorry for such a delay with updates, I have been swarmed with school work and haven't been able to make free time to work on my light but I have some updates to share. The major update is I have changed the design of my light quite a bit. I had to redesign the light and eliminate parts due to limited availability of the CNCs for personal projects. The new design is much more manual machine friendly, with the only part needing to be CNCed is the tube, and that is only for the curve in it. Second I have decided to go off in a strange direction with the switch on this one. In an effort to make something unique I plan on using magnets to hold the button in place

 

Flashlght v2 Overview

 

Today I have started working on the machining of it. The first part I am working on is the head/pill as I want to make sure all of the components fit nicely before working on the other parts. I am making the body and head from 6061-T6 Aluminum and I plan to make the bezel, tailcap and switch from stainless steel. All materials that I am using are scraps from the shop, so I am not sure if I will have the right materials for everything, fingers crossed I will.

I found some crap 1 1/2" Aluminum round which is long enough for my part.

First I turned down a length of the the round to the correct OD

 

Then I turned down and cut the relief for the threading.

 

Unfortunately I have to stop for class for now, however later today I will be working on it more and post some updates and hopefully I can finish the head today.

 

MtnDon
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Good to see what you have done!

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It’s great to see the progression of your build xqwerty151x. I’m interested in seeing your magnetically retained button idea and glad you joined the comp Smile

  

xqwerty151x
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As promised, another update.

Started out by drilling out a hole for the Driver by using two different endmills. I set up an indicator to get more accurate depth readings as the tailstock has quite a bit of play.

I added this ledge so the Driver can sit raised up and the components and wires won't be smashed together.

Next, I tried my hand at single-point threading, and I was pleasantly surprised by the results. I ended up using 1 1/8-20 threads. I probably could have gone with smaller threads and overall light but I decided to play it safe with this size.

Next, I parted off the part and turned it to length, and again drilled out a hole, except this time for the MCPCB. Since we did not have an endmill or drill the correct size I got out the boring bar and brought them to size.

Lastly, I turned down, cut relief, and then threaded the other side of the part, again in 1 1/8-20.

Started to get late so I ended up calling it for tonight. I have a date with the super seter tomorrow to drill the hole for the button.

More updates to come tomorrow!

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You could cut that curve on a manual lathe by plotting points and using a tool with a large radius to perform the cut. Then smooth with a half-round file and finish with sandpaper.

Natewar
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Nice light kinda looks like a WUBEN C5 mini

G0OSE
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Love someone else is using a lathe, nothing like my old 1900’s one lol!
I wish I was able to cut threads on mine but sadly it’s almost impossible and it holds me back a lot that I can’t do it, or even know how.
Something I wish to change in the future. Realy looking forward to seeing the finished article!

wcddesign
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cool tools. product sounds promising.

xqwerty151x
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Yeah, our school shop has almost every tool I could want to use, short of forging equipment. We have 6 manual lathes and mills, 2 CNC mills, 3- 2/3 axis CNC lathes, and one 7/11 axis CNC lathe (depends if you count the sub-spindle as extra axis), EDMs, waterjet, pneumatic threader, sandblasters, a whole woodworking shop with two CNC routers, two SawStop table saws, welding shop and a lot more. It is like a playground for me, and the best part is that engineering students don't have to pay (outside of tuition/fees).

Unfortunately, I have started to run out of time, with the shop being closed for Thanksgiving and exams looming I might not be able to finish my light. I submitted my files to get made on the CNC lathes but with senior design projects also finishing up, it might not be able to be made before the 8th. If it does get made I will definitely try to take a timelapse of the CNC doing its thing. Even then I still have to get the electronics all figured out.

 

wcddesign
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Well, good luck on finding time. This is my weakness, for life! :).

I don’t know how long is left for the contest, but I’m about out of free time to spend working on it anyway. I am supposed to make pocket organizers for the kids (to hold victorinox knife, lumintop edc01, and rite in the rain plastic variant of Fischer bullet space pen) out of an old suede coat… If I can. Have to try.

I may be crazy but I think that if you know what you’re doing, you probably shouldn’t be doing it, :P. What’s to be learned?

pinkpanda3310
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xqwerty151x wrote:
… If it does get made I will definitely try to take a timelapse of the CNC doing its thing.

That would be awesome to see, fingers crossed Big Smile

  

MtnDon
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wcddesign wrote:

I don’t know how long is left for the contest,….

I may be crazy but I think that if you know what you’re doing, you probably shouldn’t be doing it, :P. What’s to be learned?

Countdown timer… is in the first post here.

For me, if I know what I am doing and am doing it again, it is because I derive enjoyment from it.

xqwerty151x
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wcddesign wrote:
Well, good luck on finding time. This is my weakness, for life! :).

I don’t know how long is left for the contest, but I’m about out of free time to spend working on it anyway. I am supposed to make pocket organizers for the kids (to hold victorinox knife, lumintop edc01, and rite in the rain plastic variant of Fischer bullet space pen) out of an old suede coat… If I can. Have to try.

I may be crazy but I think that if you know what you’re doing, you probably shouldn’t be doing it, :P. What’s to be learned?

While it seems like I might know what I am doing I promise I don’t. This project was a combination with a school class for product design so most of the work went into the design so I hit all of the deliverables for the class, making the flashlight was just a happy byproduct of the class.
In terms of machining, I work at my school’s machine shop but I still have lots of things to learn about machining. For example, this was my first time doing single point threading and while the part turned out nicely, it also turned out as left-handed threads instead of right-handed threads. I also picked up tips along the way such as using the indicator on the tailstock for more precise drilling depth, little things like this that I can pass on to other students when they have similar parts.
The machining process is simple in theory, measure, turn, drill, measure again, realize you are .100” undersized because you read the caliper wrong, curse, repeat. I don’t care to admit how many mistakes I have made working on just those two parts but I also enjoy the process of taking an idea from my mind and then physically holding it in my hand and that makes up for all of the effort it took to get there.