3D-printed DIY LED light

Summary

I think I just went through the exercise when anyone who buys a 3d-printed and seriously gets into CAD software does -- design his own lamp.

I built my video light, because this is what I'm using it for.

Here's the video of the assembly process

DIY LED COB 3d-printed lamp on youtube

Here's the brief walk trough the source code.

DIY LED COB 3d-printed lamp openscad design walkthrough on youtube

Design & Source Code

I worked on the project on and off, rewriting the design once, and learning a lot of things in-between, so it has some old openscad paradigms, like removing cubes from cubes; and some of the more recent things -- like using primitives from NopSCADlib.

Here is the source code for the lamp -- https://github.com/avolkov/openscad-designs/tree/master/video-light

Print files with descriptions on prusaprinters -- https://www.prusaprinters.org/prints/75338-diy-100w-led-cob-video-light

Print files with descriptions for the articulated mount on prusaprinters -- https://www.prusaprinters.org/prints/75428-articulated-mount-for-light-stand-bracket

All of my code is is under Attribution-ShareAlike 4.0 International (CC BY-SA) https://creativecommons.org/licenses/by-sa/4.0/.

The original bowens mount is under Creative Commons attribution license, made by hasherdk and can be found here -- https://www.thingiverse.com/thing:3824025

BOM

Hardware

  • 4x M8 40mm bolts
  • 4x M8 nuts
  • 2x M3 10mm bolts for mounting handle
  • 2x M3 30mm bolts for 12v power module
  • 2x M3 35/40mm bolts for led driver
  • 4x M3 nuts for holders of power modules
  • 2x M5 14/16mm bolts for attaching articulater mount
  • 2x M5 nuts for attaching articulated mount

Electrical

  • 1x 100W LED COB
  • 1x 100W LED COB driver (I got 40W one by mistake)
  • 1x 100W LED Aluminium heat sink with 80mm fan and 60 degree 44mm lens, with bolts for mounting lens and light COB.
  • 2x Latching toggle switch
  • 1x 12v DC power supply (I sacrificed a 12V 1A wall wart from a long-dead external hard drive)
  • 1x 5x7 Prototyping board
  • 3x JST 2-pin male connector
  • 3x JST 2-pin female connector
  • 1x 2-wire extension cord
  • 2x 3-contact wago connector

3D printing material

  • Bowens mount is made out of ABS
  • Shell is made out of PLA. Always turn on a fan or the shell will melt.

Conclusions and updates

Making this was fun. When I tried out the lamp it turned out to be pretty useful, but I found the following things that can be improved

  • Ground the heat sink. It's only 36V 1.5A, but safety first.
  • Replace extension cord 2-wire cable with a proper IEC 320 C14 socket, that would also bring a ground wire into the shell
  • Wiring for the led cob should be routed better
  • Fan should be either automatically regulated or always on, I already forgot to turn it on once and it almost melted the case.
  • Using PWM regulators between LED driver and COB may let me adjust light intensity
back to top