This will be a thread to get gaskets created by the community for any flashlight. This is mainly for Convoy since the focus isn’t always fine-tuned, especially when there’s a new batch. I can create them when I can find the time.
For requests you need to provide the following:
• Outer diameter of the base
• Reflector hole diameter
• Thickness where the reflector sits
• Full thickness/height of the gasket (can be helpful)
• Emitter footprint
• Perhaps a photo of the shelf and reflector or a photo of an existing gasket
I’m trying to learn 3D printing, and wonder if the filament printers have enough precision to print these gaskets well? We have 0.4mm diameter filament, which I suspect might be too thick to have reasonable precision. Should I look into SLA printing instead of FFF?
Also: I recall seeing somewhere that you also have a one-piece design for the gaskets, but couldn’t find the thread. If you indeed have such a design, would you put it into this thread? Thank you very much in advance.
An ignorant question: are those gaskets suppose to position the LED better than the original arrangement? For instance, what to expect from using one in 3x21D vs. leaving it alone?
My naive understanding was that positioning the led within the reflector can improve the beam consistency, but that’s a trial and error procedure for each light.
Resin printers are much better, they’re just messy so I’m told. Filament printers are faster for trial and error prints, so better suited for myself. 0.2mm nozzle would be much better, but if I switched to that then I can’t use my carbon fibre filaments without clogs. 0.4mm is good enough for what I need. Easy to swap, but as I mentioned it’s good enough.
I do have one piece gaskets, I just haven’t uploaded them. I’m off on holiday so I can’t do that until I’m back.
Centring just provides a nicer beam profile and throws a little better. Height changes are what changes the focus.
The 3X21D is fine with the default gasket, it’s just not always dead centre and I like to correct that for customers. I sell for a decent profit so I like it to look and perform the best it can. I also have to sand the cell slots because they’re sharp and cut the wraps.
Here you mention carbon fiber filaments; I recall ABS filament being mentioned on thingiverse. Which do you prefer? I’ve heard that PLA softens at around 60 degC, which explains why you switched to the alternatives. I’m worried that a dark filament material would absorb too much light and heat up fast.
I personally use ASA for 100°C softening temp, you need higher temp resistance for some Convoy models. My review of the M21J peaked at 90°C before I switched on a fan. PETG at 70°C should be enough though.
Don’t use any dark filaments, found that out the hard way by destroying a reflector with a smoking gasket lol.
ok, so I tried printing some gaskets a while ago.
0.2 mm nozzle
ABS or ASA
started with darker colors, then ordered light colors
The detail and accuracy of the print is enough, they don’t distort anything. For prints this small, you typically don’t need to worry about heated chambers or anything. They print quickly.
The quality isn’t as good as the purchased / professionally manufactured gaskets overseas, but they are usable. From what I can see or guess; the gaskets made in Asia are probably nylon or a composite type material?
Slightly off the topic of 3D printing: if I can’t print the 3x21D gasket, are there any gaskets the can be bought from Convoy or elsewhere and is it worth trying or just consider the beam good enough as it is (it’s not that bad)?
Is it s centering issue or focusing issue? If the issue is with focus, use sandpaper to lower the gasket or tape to raise it. If the problem is with centering, it’s more difficult. I tend to find some almost-suitable gasket and cut notches into them for the LED corners. Sometimes even the stock gasket might work if one cuts notches in a different orientation.
I tried PETG as the first filament for the gaskets. The deform relatively quickly in my lights. My lights are very much on FET drivers, so on the higher end of power. PETG isn’t enough for DD lights, at least not for me.
All my non-printed gaskets are from Aliexpress or nealsgadgets. They all work fine, focus and beam are perfect.
I think printed gaskets are great for:
custom lights and custom emitter/reflector combinations
custom hosts or MCPCBs or some scenario where a standard gasket won’t fit or work
But printing in ASA or ABS is tricky, it usually requires an up-to-date printer that handle the temperatures and material. An out-dated Ender won’t print ABS unless it was seriously upgraded with a new hotend and has a way to deal with VOCs.
PETG shouldn’t deform under 70°C, so you must have been reactivating turbo to get it high. Usually PETG is plenty for flashlights with regulation at 50-60°C.
I’m away on holiday, but at home on my computer I bookmarked a new carbon fiber filament that can handle 200°C+ and prints perfectly without an enclosed printer.
Wouldn’t you require a larger diameter nozzle for carbon fibre to stop blockages? Which would affect how well the gasket fine detail will print.
I’d think the temperature right at the LED would peak substantially higher than the driver’s set maximum temp.
I’ve got a SFH55 in a FT03S and they’re an odd 11 x 10mm, plus the reflector hole is a massive 17mm. The only other LED option (I can think of) that will fit straight in is a SBT90.2 . That’s one I’d like to print gasket for - so I can fit other sized LED’s. I’ve even searched for other reflectors that will fit and there’s no exact match.
My printer can do ABS / ASA and is enclosed (DIY enclosure with a filter/ fan) - it’s the fumes I’m concerned about as it’s inside.