--- /dev/null
+// A simple adjustable diffuser for the LED flashlights.
+//
+// Designed by Jan "Yenya" Kasprzak <kas at yenya.net>.
+// Distributable under the terms of the Artistic License.
+//
+// Tested with ZHISHUNJIA ZSJ-T29 LED flashlight (dx.com SKU #317226).
+// NOTE: I can't really recommend this particular flashlight, it is
+// well below the specs (600/300/150 mA instead of stated 2.4 A).
+//
+// For any other flashlight, adjust the parameters below:
+
+// the true _diameter_ of the flashlight + some space around
+ring_d = 34.3 + 1.0;
+
+// the diaphragm thickness, set so that it is printed with two print layers
+diaphragm = 0.5;
+
+// outer wall thickness - preferably the integer multiple
+// of the print trace width
+wall = 1.5;
+
+// height of the center of clip beams + some space below + diaphragm thickness
+clip_h = 7.3 + 0.5 + diaphragm;
+
+// the clips protrude this much to the inner cylindrical hole
+// the bigger value means more stiff fit
+clip_w = 1.2;
+
+clip_angle = 120; // at least 90 degrees; bigger is easier to put on and off,
+ // smaller is more stiff, but harder to remove
+
+n_clips = 3; // number of clips; odd numbers prefered
+
+// the height of the clip is computed so that there is wall/2-wide flat
+// on top of the clip
+clip_top = clip_h + (clip_w+wall/2)*tan(clip_angle/2);
+
+// the overall height:
+// ring_h = clip_top; // cylindrical shape without the clips protruding on the top
+ring_h = clip_h + wall; // clips protruding on the top
+
+infty = 100;
+eps = 0.01;
+
+module diffuser() {
+ difference() {
+ // outer cylinder
+ cylinder(r = ring_d/2 + wall, h = ring_h);
+ // inner cylinder hole + diaphragm
+ translate([0, 0, diaphragm])
+ cylinder(r = ring_d/2, h = ring_h);
+ translate([0, 0, ring_h + eps - wall])
+ cylinder(r1 = ring_d/2, r2 = ring_d/2 + wall/2, h = wall);
+ }
+ // clip beams
+ for (angle = [0:360/n_clips:360-eps]) intersection() {
+ rotate([0,0,angle])
+ translate([ring_d/2-clip_w, -infty/2, clip_h]) {
+ rotate([0, 90-clip_angle/2, 0])
+ cube(infty);
+ rotate([0, clip_angle/2, 0])
+ cube(infty);
+ }
+ cylinder(r = ring_d/2 + wall, h = clip_top);
+ }
+}
+
+diffuser();
+
+++ /dev/null
-// Diffuser for ZHISHUNJIA ZSJ-T29 LED flashlight (dx.com SKU #317226).
-infty = 100;
-eps = 0.01;
-
-diaphragm = 0.5; // diaphragm thickness
-wall = 1.5;
-
-ring_h = 12; // the height of the body
-ring_d = 34.3 + 0.5; // the lens ring diameter + tolerance
-
-clip_h = 7.3 + 0.5; // height of the clip above the diaphragm
-clip_dist = 1.5;
-clip_size = 1.2;
-
-
-module diffuser() {
- difference() {
- cylinder(r = ring_d/2 + wall, h = ring_h);
- translate([0, 0, diaphragm])
- cylinder(r = ring_d/2, h = ring_h);
- for (angle = [0:120:360]) rotate([0,0,60+angle]) {
- translate([0, 0, 20+clip_h])
- rotate([0, 90, 0])
- cylinder(r=20, h=infty);
- }
- }
- for (angle = [0:120:360]) rotate([0,0,angle]) {
- intersection() {
- hull() {
- translate([ring_d/2-clip_dist, -infty/2, clip_h])
- cube([infty, infty, clip_size]);
- translate([ring_d/2+wall/2, -eps/2, ring_h+wall])
- cube([eps, eps, eps]);
- }
- cylinder(r = ring_d/2 + wall/2, h = ring_h);
- }
- }
-}
-
-diffuser();
-
--- /dev/null
+eps = 0.01;
+infty = 100;
+
+module chamber() {
+ hull() {
+ for (i = [-1, 1]) {
+ translate([-3, 0, 0.5])
+ scale([1.25, 1, 1])
+ cylinder(r1 = 8, r2 = 9, h = 4, $fn = 3);
+ rotate([0, 35*i, 0]) {
+ translate([0, 0, 7])
+ rotate([0, 0, 45])
+ cylinder(r = 10/2, h = 4, $fn = 4);
+ }
+ }
+ }
+ for (i = [-1, 1]) {
+ rotate([0, 35*i, 0])
+ translate([0, 0, 10])
+ cylinder(r = 6.0/2, h = 5, $fn = 6);
+ intersection() {
+ rotate([0, 35*i, 0])
+ translate([0, 0, 15-eps])
+ cylinder(r = 8/2, h = 10, $fn = 6);
+ translate([-30/2, -15/2, eps])
+ cube([30, 15, 15]);
+ }
+ difference() {
+ translate([-32/2, -16/2, 15])
+ cube([32, 16, 20]);
+
+ translate([screw_x-12/2, screw_y-12/2,0])
+ cube([12, 12, infty]);
+ }
+ }
+
+}
+
+screw_x = 5;
+screw_y = 11;
+
+module body() {
+ hull() {
+ // top cube
+ translate([-36/2, -20/2, 15])
+ cube([36, 20, 5]);
+ // bottom triangle
+ translate([-3, 0, 0])
+ scale([1.5, 1, 1])
+ cylinder(r = 11, h = eps, $fn = 3);
+ // screw base
+ translate([screw_x-12/2, screw_y-12/2,17])
+ cube([12, 12, 3]);
+ }
+}
+
+module light() {
+ difference() {
+ body();
+ chamber();
+ // screw head hole
+ translate([-4+screw_x, screw_y-8/2, 17-infty])
+ cube([8, infty, infty]);
+ // screw hole
+ translate([screw_x-4, screw_y-4/2, -eps])
+ cube([8, 4, infty]);
+
+ // cable hole
+ translate([-9-eps, 0, 17])
+ cube([8, infty, infty]);
+
+ // debug
+ // translate([-infty/2, -infty, -infty/2]) cube(infty);
+ }
+}
+
+light();