I've been slowly working on making a flashlight using ~30 UV LEDs. One inevitable chore in that project is making a "disk" of some sort with 5mm holes to hold all the LEDs. My son-in-law just got himself a 3D printer (resin type) for Christmas and so it seems to me that might be the best way to make the disk. I have a drill press but was not looking forward to drilling all those holes by hand.

Here's the question: Do you have a template that might save me some design time? I can't possibly be the first person to 3D-print a holder for LEDs. But where might I find a template? I'm even considering designing a snap-in arrangement so that I don't have to glue them in place. One or two is easy but 30 is tedium.

 

Are you mounting the LEDs to a circuit board? (I can't imagine wiring them otherwise.) At JLCPCB and other Chinese fabs, you can have 10 boards made for five bucks. Or have an aluminum-backed board made for around $20 for heat sinking.

If you're going to use a pcb (or even if not), you could make an "alignment" pcb with only 5mm holes and white soldermask that will position the LEDs and serve as a reflector as well.

Using JLC's free EasyEDA software*, it would be pretty simple to lay out an array of LEDs. It will work in polar coordinates, and automatically position an array. Specify number of LEDs, the radius and angle between each and click it's done.

* I recommend the "standard" version of EasyEDA rather than the "pro" – it's got a short, shallow learning curve.

 

FYI I read a Reddit post yesterday from a guy in the US who's $500 PCB order from JLC is being held up for a $200 import duty fee the shipper would process. Pay me now or we send it back AND charge you shipping both ways.

 

If you do go the 3D printer route, make sure to use a high melting-point plastic.

 

I have parts coming from AliExpress. I received a notice today from USPS that expected delivery is Saturday. There's no mention of fees due. Fingers crossed.

 

If you do go the 3D printer route, make sure to use a high melting-point plastic.

The LEDs I'm using are the typical 5mm, ~20mA ones. They don't get very warm. But yeah, I realize that packing 30 of them tightly together is an issue.

 

Are you mounting the LEDs to a circuit board?

No, I'm thinking more of dead bug wiring. Insert LED into plastic holder, fold, cut and solder leads directly to neighboring LEDs.

 

Done on TurboCAD 14 (2D). You can use the layout if you have TurboCAD 14.
I can't attach the TC file. PM me with your email address and I'll send you the TC file. If you want.

 

I am the lazy sort, and I definitely prefer soldering things to a pcb rather than soldering leads together.

This took literally 5 minutes to lay out in EasyEDA. I plopped down 16 LEDs, said to arrange them in a circular array of 20mm radius, with 22.5 degrees between LEDs, and CLICK. Done. Additional rings would be just as easily added. It would be a lot simpler than putting LEDs in holders and soldering then dead-bug style. It's at least something to think about. Especially if you want more than one.

 

Love it! Glue the LEDs in, no PCB needed. In my experience Super Glue works well on PLA plastic. You could even make a battery tube for it.

 

My battery tube will be a length of 1.5" PVC drain pipe with two 18650 batteries in holders. I'll be posting more of my project details in my Yuperlite thread. For now I'm just looking for an LED holder with the details worked out. For instance, the precise diameter to specify for a 5mm LED. I'd love it if the LEDs fit but are just snug enough to hold themselves in.

 

Especially if you want more than one.

Well there's the rub. At most I'll make two of these and I'm not keen to spend much. There's no point to it if I end up spending more than just buying a commercial UV flashlight. I might even balk when I find out what the printing resin costs.

 

PM me with your email address and I'll send you the TC file. If you want.

Thanks Tony, but no thanks. I don't have any problem creating a 2D drawing. I'm not very good at it but I can also produce the required 3D file in SketchUp. What I'm after are the little design details - the experience of others - that might make the design better than a first-run prototype.

 

I've always used 0.203"

 

At most I'll make two of these and I'm not keen to spend much.

Just offering a suggestion to make things easier, that's all. Five pcbs at JLC should cost $2, with "slow boat" shipping costing maybe $15.

 

Finding some useful stuff at Thingiverse, a huge repository of 3D printer files.

eg. https://www.thingiverse.com/thing:3117990

 

I know this won't help the OP, but it might help others; I am enjoying reading the various "solutions", though:

I recently "found out" that the plastic shells used on mini-incandescent xmas lights can hold a 5mm LED - if you shave off a bit of it around the plastic base of the LED (it can be press-fitted); a 3mm LED will easily fit - and I found that a 3mm LED will even fit inside the tubing used for the bulbs!

So (in theory) - if you can cut the bulb glass away at it's base - you could make your own LED xmas lights, that look like real mini-incandescent bulbs (with a bit of work) - probably not worth it, ultimately. Plus you still need a resistor for each one...and so forth (and they likely sell such lights - but who knows where the prices will go by next xmas!)...

I found this out after one bulb burnt out in a brand new set (thought I was getting LEDs - but nope) - so I took the whole string apart for parts (I scrounge that way)...and though, "hmm...will this work?" - because I might want to mount an LED in a project box or something, and I don't have many of the bezels - and I can't really spend the money (well, shouldn't - I'm unemployed right now)...

Thought I'd pass on the info...maybe someone can use it?

 

Big Clive on YouTube has a number of OpenScad files for making LEDs lenses of many difference shapes for LED Christmas lights using a 3D printer.

 

Do you have a template that might save me some design time? I can't possibly be the first person to 3D-print a holder for LEDs. But where might I find a template?

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