µSpotLight

thingiverse

How many times I needed to enlighten an object from different angles and didn't find adequate support to hold flashlights. Edit: 20/08/2016 Added the "one-piece" BaseLeg versions. this project... How I Designed This Overview & Background: Let's describe why I started this project. I have many LED torch lamps, different sizes and shapes. I would like to create a universal torch lamp holder that is adjustable in elevation, meaning up and down. Okay, maybe "universal" is too much for what I did; let's say it's suitable for the flashlights I have. I wanted something easy and fast to print. Strong enough to be handled constantly. Easy, you said? Hum... In fact, I had to make several versions before I felt satisfied. Anisotropy The first thing that comes to mind when I think of the final shape idea is how I will print it in order to have optimized orientation on the X/Y printer axes. Always thinking about anisotropic effects like someone working with wood needs to follow fiber direction, you need to care a lot about this. In my opinion, most of the time, the In-One-Time-Printed-Piece is not a good solution for many reasons: The object will not be optimized for all axes constraints. The object will need more Z axis access (meaning longer printing time). The object will certainly need structure support material to fix overhanging. That's why this print process preparation is very important. Instead of building the base and leg in one piece, I designed the base and leg in two pieces, to have the base layers oriented horizontally and the leg vertically. I will have to glue these two parts, but the final result will be stronger than if I did it in a single piece. Plus, the printing will be faster because it's not printed in height. As usual, you can use any 3D software to design, more over when it's based on simple shapes like this project. In my case, I used Rhino. If a picture is worth 1,000 words, what about an animation? It makes you thirsty... Here is a quick'n'dirty demo how I designed the µSpotlight with Rhino. It's not a tutorial; it's just to show how easy it is to learn 3D software. When shapes of figures are defined by curves, only three tools are used: Extrusion Boolean operation: Difference (in order to cut out) Fillet edge (on the animation you just see the unfolded menu) Nothing more... Objectives: A basic approach of CAD modeling From theoretical idea to get to the real object. Audience: If we were 10 years ago, I would have said a project like this one can only be made by young people starting around 18/20 years old. Nowadays, kids are familiar with computers far younger, so we can say a project like this one can be started by kids 12 years old, maybe less; again that depends what we want to demonstrate. Skills Learned: The goal is learning how to achieve a project from the idea to realization. The idea will be modeled on a computer, then printed. It allows you to have an approach on mechanical properties of materials in this case plastic. It's interesting to experiment with different types of plastic such as ABS, PLA, Acrylic, Nylon, and more. Duration: It's always difficult to give an estimation; it depends on the involvement: For young students, I guess a project like this one will allow you to "touch" 3D printing from conception to print without going deep into each subject. The teacher will be there to drive the little hands. For older students, we can begin to go deeper into each tool and teaching. Let say respectively from a day to a month. Preparation: The students need access to a computer. A 3D software installed. Some flashlights in order to have some models to try with. Bolt and screw M4x20 + screw driver. A 3D printer, of course. The vertical leg is inserted by force into the base; glued for PLA, acetone for ABS. About the large base, before to glue anything, take care about the leg Base orientation. The leg bent to the outside base direction in order to have an equilibrated supporting. Look at the second picture to understand what I mean. Result: 2 kind of grip holders: One is a unique fixed diameter and the other more flexible depends on the tightening of the screw. 2 longer legs long. Medium. 2 base shapes Round. Oval (for longer torch lamp).