Bar installed – light off vs on

Design being printed vertically for best edge definition

CAD model

Prototypes (from bottom: 1, 2, 3) – hinge detail

Prototypes (from right: 1, 2, 3) – bracket detail

What:

• Bracket for a strip of LEDs for desktop 3D printers
• Published here: https://www.thingiverse.com/thing:2958738

Why:

• Increased light directly on printer’s nozzle, to better monitor print quality
• Nothing currently exists to satisfy the need

Features:

• Hinged – adjustable light angle, ability to move completely of the way
• Minimal Footprint – to minimize obstruction of user’s vision
• Built-In Light Diffusion – to soften harsh LED pinpoint lighting
• Easy Installation – no disassembly or additional fasteners required
• Multiple LED sizes – works with 5050 or 3528 LED strips
• Optimized for 3D Printing
  • One piece
  • No supports necessary
  • Printable by wide range/quality of consumer-level 3D printers

How:

• Prototype 1 – Proof of concept
  • 1 piece design
  • C-shaped LED bracket
  • Screw holes
  • Partial printing failure due to model orientation
• Prototype 2 – Hinged concept
  • 2 piece nested design – printed simultaneously
  • C-shaped bracket w/ 1 end cap and slide-in light diffusion plate
  • Fastener slots for easy installation
  • Printed vertically to avoid need for supports
  • Designed to match LED’s 120 deg beam angle
  • Tighter dimensions
• Prototype 3 – Integrated Light Diffuser concept
  • Rectangular cross-section – increased overall part strength and rigidity
  • Printed entirely in transparent PLA plastic – eliminates need for slide-in diffusion plate, lower complexity, lower part count
  • Wall thickness can be adjusted to increase/decrease light diffusion
• Prototype 4 – Curved concept (scrapped)
  • Bracket curved along x-axis to hide LEDs from user vision entirely and minimize light glare
  • Difficult to orient and print without problems
• Prototype 5 – Final Release
  • Moved hinge to alternate side of bracket – reduces max part length from point of rotation == ensures printer nozzle is never obstructed from view
  • Adjusted hinge’s internal dimensions to create “sticky” hinge to stay in place