This was my first foray into using Fusion 360 as a CAD software. Till this time, I was mainly working on Sketchup Make which now feels like MS Paint compared to Fusion. The biggest issue I faced with 3D printing was the failure of prints. This, I still feel, is one of the biggest challenge in 3D printing. I wanted to explore with an MVP for printed lamps that can be printed in parts to ensure I reduce my risk of failure rates while still being able to churn out products at pace with some sort of customization. Along with this, I also wanted to standardize on the internal BOM and circuitry so that I could build stock piles of the same, if I ever got orders. So I had a standard 18650 cell fit into this, with required charging and protection circuits. There is also an CCS circuit for the LED modules, and I went with dual 1W LED here to ensure none of the were over driven while getting sufficient brightness. Although this was easier to produce, the end result looked like the usual Chinese knockoffs, but to my surprise, this lamp lasted for 4 days on "power on" mode.
The battery bay
This is the first layer of the lamp, which holds the 18650 cell; a holder, coz never solder on 18650; and brackets to hold the charger circuit. So this was my attempt to internalize the power module (as against to using external power bank in my previous project).
Bottom Base Fitted
Although this was unit 2 of the same design, I guess this will make it clearer to understand how the fitment was done. So I had designed the 4 bolts to hold down on the base battery bay while giving an indentation on the lip. This was to help with the friction fitting of the top diffuser part.
Final Fit & Finish
Ok, I got the base printed in yellow as well, for some consistency. And finally, with everything fit and finished, this was how it turned out to be. A very unassuming lamp, which took about 4 hours to charge its little 18650 battery. Now, I didnt measure the exact lumens this puppy threw out, but it was good enough to make sure you weren't wallowing in darkness when there was a powercut.
Le Diffuser
This was going to be the portion of this lamp that would really get the razzle dazzle from the 3D printer. So the idea was to have the base standardized and the diffuser to be of different shades and shapes. The diffuser was friction fitted on to the bottom base unit, so the user could choose his design and color to later pimp the lamp if they ever wanted to. For the prototype I went with a conservative white and in unit no. 2 I tried transparent filament (pic in top carousel)
Unit No.2
You won't believe it, I actually had a customer for this! So yeah, I put my earnest effort to ensuring he got a good product (which he did, till the moment when the slide switch got pushed inside). The transparent diffuser actually made the light brighter, you'll see the actual lighting efficacy in the next image.
In All Its Glory!
So yea, I'll conclude this project with this image. This should give you some sense as to how the light performed it's core function, which is, *drum rolls* lighting. I shouldn't have thrown light on to the fact that my work bench is really messy, but meh, at least you got a glimpse of this project. A closure, if i must say. Thanks for your patience!
As the name suggests
So this is a break down of the modular mess of a project in 1 go. Lets say a photographic version of tl;dr. As you can see, I had made this as 3 layers. The thought was to let the user change the top shade to whatever color they want, which could be printed.
The LED tray
This was designed to be the shielding between the ugly cabling, PCBs, the LEDs and the diffuser. This had to be stiff to ensure there was no buckling even if I stuff the cables into the battery bay (welp! that's not a good idea). Well, I needed the extra clamping force to hold the USB input boards (TP4056 charger board) firmly in place, as I always observe people aren't really kind to the sockets while plugging devices for charging. This LED tray also had to be reflective enough to make sure the diffuser was sufficiently lit.
